Abstract
Based on a comprehensive experimental study, single toroidal roller burnishing (STRB) of the 2024-T3 Al alloy can be successfully implemented as a mixed burnishing process. Optimum values of various governing factors provided minimum roughness and significant enhancement of the fatigue life of the treated specimens. With a planned experiment, regression analysis, and optimization procedure based on a genetic algorithm, the optimum factor values were established under a minimum roughness criterion. The derived model predicted a minimum roughness Ra = 0.074 μm. The experiment with optimal process parameters provided an average roughness (Ra) of 0.01 μm. STRB under these optimal conditions yields a relatively homogeneous surface in terms of microhardness with a surface microhardness increase coefficient of 37.6%. The parametric study of the residual surface hoop and axial stresses conducted via X-ray stress analysis shows that the STRB with near-optimal process parameters introduces significant residual stresses. STRB of the 2024-T3 Al alloy, implemented as a mixed burnishing process, produces a mirror-finish surface, improves the fatigue life by more than 2000 times, and increases the conventional fatigue limit by 35.1% compared to the reference condition.
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Abbreviations
- CNC:
-
Computer numerical control
- HBB:
-
Hydrostatic ball burnishing
- LPB:
-
Low plasticity burnishing
- MST:
-
Mechanical surface treatment
- SRB:
-
Single roller burnishing
- STRB:
-
Single toroidal roller burnishing
- A 5 :
-
Elongation
- D :
-
External diameter of the toroidal deforming roller
- d :
-
Workpiece (specimen) diameter
- f :
-
Feed rate
- F b :
-
Burnishing force
- k HV :
-
Surface microhardness increase coefficient
- n :
-
Number of passes
- N :
-
Number of cycles to failure
- r :
-
Radius of the toroid of the toroidal deforming roller
- R :
-
Cycle asymmetry coefficient
- R a :
-
Surface roughness
- s i :
-
X-ray elastic constant
- v :
-
Burnishing velocity
- x i :
-
Coded variables
- \( {\tilde{x}}_i \) :
-
Natural variables
- Y Ra :
-
Objective function of the roughness
- σ−1 :
-
Fatigue limit for symmetrical cycle
- σ u :
-
Ultimate stress
- σ Y :
-
Yield limit
- \( {\sigma}_t^{res} \) :
-
Residual hoop stress
- \( {\sigma}_z^{res} \) :
-
Residual axial stress
- ψ :
-
Transverse contraction
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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,” no. BG05М2ОР001-1.002-0023.
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Duncheva, G.V., Maximov, J.T., Dunchev, V.P. et al. Single toroidal roller burnishing of 2024-T3 Al alloy implemented as mixed burnishing process. Int J Adv Manuf Technol 111, 3559–3570 (2020). https://doi.org/10.1007/s00170-020-06350-2
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DOI: https://doi.org/10.1007/s00170-020-06350-2