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Improvement in surface integrity of CuAl8Fe3 bronze via diamond burnishing

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Abstract

The single-phase CuAl8Fe3 aluminum bronzes possess good strength and resistance to fatigue as well as high corrosion and wear resistance. Since this alloy contains less than 8.5% aluminum, it cannot be heat treated. Therefore, improvements in surface integrity (SI) can only be achieved via mechanical surface treatment. This article investigates the influence of the basic diamond burnishing (DB) process, as well as additional factors, on the SI characteristics of CuAl8Fe3 bronze. Using experiments and regression analyses, a multi-objective optimization of the DB process has been accomplished via non-dominated sorting genetic algorithm (NSGA-II) and optimal values of the factors have been established. Using these factor values, the SI characteristics of diamond-burnished CuAl8Fe3 specimens have been quantified. The conclusion has been reached that the DB of CuAl8Fe3 bronze can be implemented as mixed burnishing, i.e., DB results in a favorable combination of the height and shape parameters for the surface texture, very low roughness (nearly mirror surfaces), large (in absolute value) residual hoop and axial stresses at depths greater than 0.8 mm, high surface micro-hardness and strongly expressed grain-refined microstructures at depths of up to 0.15 mm. These SI characteristics suggest a significant increase in fatigue strength and wear resistance of CuAl8Fe3 bronze finished via DB.

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Abbreviations

α c :

Depth of cutting

\(A_{5}\) :

Elongation

\(c\) :

Axial spring constant (stiffness)

\(d_{p}\) :

Depth of penetration

\(E\) :

Young’s modulus

\(f\) :

Feed rate

\(F_{b}\) :

Burnishing force

\(HV\) :

Vickers micro-hardness

\(n\) :

Number of passes

\(m\) :

Cyclic loading coefficient

\(r\) :

Diamond insert radius

\(R_{0,2}\) :

Yield limit

\(R_{a}\) :

2D arithmetic mean deviation

\(R_{a}^{init}\) :

Initial roughness

\(R_{m}\) :

Ultimate stress

\(S_{a}\) :

3D arithmetic mean deviation

\(S_{ku}\) :

Kurtosis

\(S_{p}\) :

Maximum peak height

\(S_{q}\) :

Root-mean-square deviation

\(S_{sk}\) :

Skewness

\(S_{t}\) :

Total height

\(S_{v}\) :

Maximum valley depth

\(S_{z}\) :

Ten-point height

\(v\) :

Burnishing velocity

\(v_{c}\) :

Cutting velocity

\(x_{i}\) :

Coded coordinate

\(\tilde{x}_{i}\) :

Natural coordinate

\(\Gamma_{x}\) :

Factor space

\(\left\{ X \right\}\) :

Governing factors vector

\(Y_{i}\) :

Objective function

DB:

Diamond burnishing

DR:

Deep rolling

RB:

Roller burnishing

SEM:

Scanning electron microscopy

SI:

Surface integrity

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Acknowledgements

This work was supported by the European Regional Development Fund within the OP “Science and Education for Smart Growth 2014-2020,” Project CoC “Smart Mechatronics, Eco- and Energy Saving Systems and Technologies,” №BG05M2OP001-1.002-0023.

Funding

This work was supported by the European Regional Development Fund within the OP “Science and Education for Smart Growth 2014–2020,” Project CoC “Smart Mechatronics, Eco- and Energy Saving Systems and Technologies,” №BG05M2OP001-1.002–0023.

Author information

Authors and Affiliations

  1. Technical University of Gabrovo, Gabrovo, 5300, Bulgaria

    Galya V. Duncheva, Jordan T. Maximov, Angel P. Anchev, Vladimir P. Dunchev & Desislava K. Drumeva

  2. Technical University of Varna, Varna, Bulgaria

    Yaroslav B. Argirov

  3. Czech Technical University in Prague, Prague, Czech Republic

    Nikolaj Ganev

Authors
  1. Galya V. Duncheva
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  2. Jordan T. Maximov
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  3. Angel P. Anchev
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  4. Vladimir P. Dunchev
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  5. Yaroslav B. Argirov
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  6. Nikolaj Ganev
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  7. Desislava K. Drumeva
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Contributions

Conceptualization—GD and JM; Methodology—GD and JM; Software—GD and JM; Experiment—AA, VD, YA, NG, DD; Data analysis—JM, GD and YA; Writing (original draft preparation) —JM and GD; Writing (review and editing) —JM and GD; Visualization—GD, JM and AA; Supervision—JM and GD.

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Correspondence to Galya V. Duncheva.

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Duncheva, G.V., Maximov, J.T., Anchev, A.P. et al. Improvement in surface integrity of CuAl8Fe3 bronze via diamond burnishing. Int J Adv Manuf Technol 119, 5885–5902 (2022). https://doi.org/10.1007/s00170-022-08664-9

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