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Smoothing, deep, or mixed diamond burnishing of low-alloy steel components – optimization procedures

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Abstract

Diamond burnishing (DB) is a static mechanical surface treatment based on severe surface plastic deformation aimed at significant improvement in the surface integrity and operating properties of the treated component. Very often, DB is unjustifiably perceived of as typical smoothing burnishing. In the present article, it is shown that DB can be conducted as smoothing, deep, or mixed burnishing depending on the particular combination of process governing factors employed. Optimizations of the DB process for 41Cr4 steel under different criteria are conducted in order to obtain the optimal parameters of different DB processes. The choices of governing factors and objective functions (roughness and fatigue limits), which are obtained on the basis of planned experiments and regression analyses, are fully justified. By means of one-objective optimizations, the uncompromising optimum values of the objective functions and the corresponding optimum values of the governing factors of smoothing and deep DB processes are obtained. A new optimization procedure for solving a multi-objective optimization task is developed in order to obtain compromise optimal values simultaneously with the objective functions and governing factors of the mixed DB process. In order to highlight the advantages of the proposed optimization procedure, the multi-objective task solution is compared with the results obtained via some known methods, i.e., the compromise weight vector and function of the losses methods.

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Abbreviations

f :

Feed rate

F b :

Burnishing force

F loss :

Function of the losses

k :

Number of subintervals

m :

Number of objective functions

r :

Deforming diamond radius

R :

Cycle asymmetry factor

R a :

(Roughness)

v :

Burnishing velocity

x i :

Coded governing factor

\( {x}_i^{\ast } \) :

Optimal value

\( {\tilde{x}}_i \) :

Natural governing factor

{X}:

Vector of governing factors

{X∗}:

Vector of optimal governing factors

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

Vector of objective functions

Y j :

Objective function

\( {Y}_j^{\ast } \) :

An uncompromising optimum value

Γ x :

Factor space

ε :

Small positive number

σ −1 :

Fatigue limit

CNC:

Computer numerical control

DB:

Diamond burnishing

SB:

Slide burnishing

SI:

Surface integrity

WP:

Working point

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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”, №BG05М2ОР001-1.002-0023.

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Authors and Affiliations

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

    J. T. Maximov, G. V. Duncheva, A. P. Anchev & V. P. Dunchev

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  1. J. T. Maximov
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  2. G. V. Duncheva
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  3. A. P. Anchev
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  4. V. P. Dunchev
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Correspondence to J. T. Maximov.

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Maximov, J.T., Duncheva, G.V., Anchev, A.P. et al. Smoothing, deep, or mixed diamond burnishing of low-alloy steel components – optimization procedures. Int J Adv Manuf Technol 106, 1917–1929 (2020). https://doi.org/10.1007/s00170-019-04747-2

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