Skip to main content
SpringerLink
Log in

Finite element analysis and design optimization of low plasticity burnishing process

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In the present study, Low Plasticity Burnishing (LPB®) process on the half-space specimen has been simulated using a 3D explicit nonlinear finite element model. The developed finite element model is then used to investigate the effect of main parameters including ball diameter, burnishing force, burnishing feed, and number of passes on the resultant profile of residual stress and plastic deformation. Due to high computational cost associated with the nonlinear finite element model and in order to practically conduct design optimization of the LPB process, the design of experiment combined with the response surface methodology has been used to develop smooth response functions to efficiently and accurately approximate the residual stress profile and plastic deformation over the entire design space. Finally in order to improve the LPB process, a design optimization using the developed response functions has been formulated to obtain the optimum set of parameters such that a deep residual compressive stress with small plastic deformation is generated throughout the thickness of component.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Zhuang WZ, Halford GR (2001) Investigation of residual stress relaxation under cyclic load. Int J Fatigue 23:31–37

    Article  Google Scholar 

  2. Grinspan AS, Gnanamoorthy R(2009) Development of a novel oil cavitation Jet peening system and cavitation jet erosion in aluminum alloy, AA 6063-T6. Journal of Fluids Engineering. 131, 061301 (8 pages).

    Google Scholar 

  3. Zhang XC, Zhang YK, Lu JZ, Xuan FZ, Wang ZD, Tu ST (2010) Improvement of fatigue life of Ti–6Al–4V alloy by laser shock peening. Mater Sci Eng A 527:3411–3415

    Article  Google Scholar 

  4. U.S. Patent 5826453 (1998), other US and Foreign patents pending.

  5. Seemikeri CY, Brahmankar PK, Mahagaonkar SB(2008) Low plasticity burnishing: an innovative manufacturing method for biomedical applications, Journal of Manufacturing Science and Engineering. 130, 021008 (8 pages).

    Google Scholar 

  6. Prevéy P, Shepard MJ (2000) Surface Enhancement of Ti-6Al-4V Using Low Plasticity Burnishing. 11th AeroMat Conference, Bellevue, WA.

  7. Cammett JT, Prevéy PS (2003)Fatigue Strength Restoration in Corrosion Pitted 4340 Alloy Steel Via Low Plasticity Burnishing. Retrieved from www.lambda-research.com.

  8. Prevéy P (2000) The Effect of Cold Work on the Thermal Stability of Residual Compression in Surface Enhanced IN718. Proc. 20th ASM Materials Solutions Conference and Exposition, St. Louis, Missouri, pp. 426–434.

  9. Prevéy P, Cammett J(2000) Low Cost Corrosion Damage Mitigation and Improved Fatigue Performance of Low Plasticity Burnished 7075-T6. Proc. 4th International Aircraft Corrosion Workshop. Solomons, MD.

  10. Rao DS, Hebbar HS, Komaraiah M, Kempaiah UN (2008) Investigations on the effect of ball burnishing parameters on surface hardness and wear resistance of HSLA dual-phase steels. Mater Manuf Process 23:295–302

    Article  Google Scholar 

  11. Loll NH, Tam SC, Miyazawa S (1991) Investigations on the surface roughness produced by ball burnishing. Int J Mach Tools Manuf 31:75–81

    Article  Google Scholar 

  12. El-Axir MH (2000) An investigation into roller burnishing. Int J Mach Tools Manuf 40:1603–1617

    Article  Google Scholar 

  13. El-Axir MH (2007) An investigation into roller burnishing of aluminum alloy 6061-T6. Proc IME B J Eng Manufact 221:1733–1742

    Article  Google Scholar 

  14. El-Taweel TA, El-Axir MH (2009) Analysis and optimization of the ball burnishing process through the Taguchi technique. Int J Adv Manuf Technol 41:301–310

    Article  Google Scholar 

  15. Klocke F, Bäcker V, Wegner H, Feldhaus B, Baron HU, Hessert R (2009) Influence of process and geometry parameters on the surface layer state after roller burnishing of IN718. Prod Process 3:391–399

    Google Scholar 

  16. Seemikeri CY, Brahmankar PK, Mahagaonkar SB (2008) Investigations on surface integrity of AISI 1045 using LPB tool. Tribol Int 41:724–734

    Article  Google Scholar 

  17. Golden PJ, Shepard MJ (2007) Life prediction of fretting fatigue with advanced surface treatments. Mater Sci Eng A 468–470:15–22

    Article  Google Scholar 

  18. Luca L, Neagu-Ventzel S, Marinescu L (2005) Effects of working parameters on surface finish in ball-burnishing of hardened steels. Precis Eng 29:253–256

    Article  Google Scholar 

  19. JiangY XB, Sehitoglu H (2002) Three-dimensional elastic-plastic stress analysis of rolling contact. J Tribol Trans ASME 124:699–708

    Article  Google Scholar 

  20. Zhuang W, Wicks B (2004) Multipass low-plasticity burnishing induced residual stresses: Three-dimensional elastic-plastic finite element modeling. Proc IMechE C J Mech Eng Sci 218:663–668

    Article  Google Scholar 

  21. BouzidSai W, Sai K (2005) Finite element modeling of burnishing of AISI 1042 steel. Int J Adv Manuf Technol 25:460–465

    Article  Google Scholar 

  22. Yen YC, Sartkulvanich P, AltanT (2005) Finite Element Modeling of Roller Burnishing Process. Annals of the CIRP, 54/1, pp. 237–240.

  23. Maximov JT, Duncheva GV (2011) Finite element analysis and optimization of spherical motion burnishing of low-alloy steel. Proc IMechE C J Mech Eng Sci 226:161–176

    Article  Google Scholar 

  24. Liu Y, Wang L, Wanga D (2011) Finite element modeling of ultrasonic surface rolling process. J Mater Process Technol 211:2106–2113

    Article  Google Scholar 

  25. Sellars C, Tegart WM (1966) On the mechanism of hot deformation. Acta Metall 14:1136–1138

    Article  Google Scholar 

  26. Johnson GR, Cook WH (1985) Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures. Eng Fract Mech 21:31–48

    Article  Google Scholar 

  27. WestmanEL (2003) Development of an inverse modelling programming system for evaluation of Ti-6Al-4V gleeble experiments. Master’s thesis, Lule˚a University of Technology.

  28. Johnson GR (1985) Strength and Fracture Characteristics of a Titanium Alloy (.06Al, .04V) Subjected to Various Strains, Strain Rates, Temperatures and Pressures. Naval Surface Weapons Center NSWC TR, 86-144.

  29. Lesuer D (2000) Experimental investigation of material models for Ti-6Al-4V and 2024– T3, FAA Report DOT/FAA/AR-00/25.

  30. ABAQUS Analysis User’s Manual, ABAQUS. Inc., Version. 6.11. 2011.

  31. Croarkin C, Tobias P (eds) (2006) NIST/SEMATECH e-Handbook of statistical methods.National Institute of Standards and Technology, URL http://www.itl.nist.gov/div898/handbook/.

  32. DuMouchel W, Jones B (1994) A Simple Bayesian Modification of D-Optimal Designs to Reduce Dependence on an Assumed Model. Technometrics 36:37–47

    MATH  Google Scholar 

  33. Russell SJ, Norvig P (2003) Artificial intelligence, a modern approach, second ed, McGraw-Hill, New York, pp. 110–116.

  34. Nocedal J, Wright SJ (2006) Numerical Optimization, 2nd edn. Springer, New York, pp 529–576

    Book  MATH  Google Scholar 

  35. Fischer-Cripps AC (2007) Introduction to contact mechanics, 2nd edn. Springer, New York, pp 137–150

    MATH  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical and Industrial Engineering, Concordia University, 1455 de Maisonneuve Blvd, West. Montreal, QC, H3G 1M8, Canada

    Farough Mohammadi & Ramin Sedaghati

  2. Rolls-Royce Canada Ltd, 9545 Cote-de-Liesse, Dorval, QC, H9P 1A5, Canada

    Ali Bonakdar

Authors
  1. Farough Mohammadi
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ramin Sedaghati
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Ali Bonakdar
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Ramin Sedaghati.

Additional information

LPB® is a registered trademark of Lambda Technologies Group.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Mohammadi, F., Sedaghati, R. & Bonakdar, A. Finite element analysis and design optimization of low plasticity burnishing process. Int J Adv Manuf Technol 70, 1337–1354 (2014). https://doi.org/10.1007/s00170-013-5406-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-013-5406-y

Keywords

Search

Navigation