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A novel ultrasonic burnishing (UB) system with a flat tool using a piezoelectric longitudinal transducer (PLT) is proposed. High-precision no-feeding mark planar burnishing can be achieved by the compact system with a size of only 280 mm 224 mm 558 mm without the need for machine tools. Above all, the structure of the burnishing system is presented and the operation principle is analyzed in detail. A resonant frequency design method of the PLT with a tool head is discussed. Based on thisthe PLT achieves the expected resonant frequency precisely. Subsequently, the test system for the PLT is built and the resonant frequency and vibration amplitude are tested, which are in good agreement with the simulation results. Ultimately, the UB experiments are carried out and the results indicate that the surface roughness of the workpiece is reduced from Ra 1.6 m to Ra 0.182 m, which is reduced by 88.31%. Furthermore, the surface topography shows that the surface without the feeding mark is generated, which is beneficial to improve the burnishing accuracy and expand the application in ultra-precision processing.

In the present research work, an attempt has been made to enhance the surface integrity (roughness and microhardness) of β-Phase Titanium Alloy using ball burnishing assisted electrical discharge cladding (BB-EDC) process. The effect of BB-EDC process parameters such as peak-current, pulse-duration, and supply-voltage on the surface roughness has been studied. For experimentation, a BB-EDC experimental set-up has been fabricated in-house on the Sparkonix die-sinking EDM machine. The experimentation has been performed according to a mixed-mode L-18 orthogonal array. The roughness was measured using a surface profilometer. The surface hardness was measured using Vicker’s microhardness tester. It has been observed that BB-EDC reduced surface roughness significantly and highest contributing factor. FE-SEM morphology investigation revealed that BB-EDC removed the surface irregularities and flat the surface, thus surface roughness decreased and finishing improved. Moreover, BB-EDC improved the surface hardness owing to comprise force generated by hard-ceramic balls. At optimized conditions, the minimum surface roughness and micro-hardness were measured around 0.61 µm and 848 HV, respectively. The obtained results show that the BB-EDC treated surface can be used for biomedical implant applications.

In the current study, a comparative study on the surface modification of β-Phase titanium alloy has been carried out using electric discharge machining (EDM) and ball burnishing assisted electrical discharge cladding (BB-EDC) process to improve the surface hardness and surface finish for the potential use of biomedical implants. The surface characteristics of Edmed and BB-EDC modified surface has been investigated. The effect of EDM and BB-EDC process parameters such as peak-current, pulse-duration and supply-voltage on the surface roughness and micro-hardness has been studied. The roughness was measured using a surface profilometer and surface hardness was measured using Vicker’s micro-hardness tester. The results show that BB-EDC modified surface exhibits high surface hardness and low surface roughness as compared with EDMed surface at any parametric condition. The in the case of BB-EDC, the maximum surface hardness (848HV) and minimum surface roughness (0.56 µm) were obtained at 5A peak current, 50 µs pulse duration, and 60 V supply voltage. Moreover, the recast layer obtained after BB-EDC process was flat and smooth with 10–15 µm thickness. The obtained surface from BB-EDC process was free from defects and can be used for biomedical implant application.

The performance and durability of orthopedic implants are mainly determined by their surface integrity. Ball burnishing (BB) is a kind of finishing treatment which improves the surface dependant mechanical properties of metallic biomaterials. In this work, this process was applied on the flat surface of 316L stainless steel to enhance its microhardness and wear resistance. The mathematical modeling of microhardness Vickers was performed by the response surface method (RSM) based on Box–Behnken plans, and the optimum regime was applied under several passes to investigate the effect of number of passes (i) on the surface properties. The evolution of microhardness, nano-hardness and elastic modulus was then examined. Wear resistance, in terms of variation of Coefficient of friction and wear loss, was also investigated. Finally, XRD analysis was performed to evaluate any change in structure produced by BB. The results show that burnishing treatment permits to raise the microhardness by up to 38.3% and to reduce the wear loss by up to 65.2%. Nano-hardness and elastic modulus were also increased after application of the process. XRD patterns indicate that grain refinement was induced with no change in phases composition. The number of passes is proved effective in increasing the depth of the hardened layer, which influences subsequently on the frictional behavior of 316L stainless steel.

Inconel 718 is a widely used alloy in the aeronautic sector due to its excellent mechanical and corrosion wear resistance under high temperature conditions. However, its good mechanical properties can be a double edge sword in terms of manufacturing, especially in those processes based in mechanical principles, such as machining or forming. Considering that most aeronautic components are exposed to cyclic load and temperature, fatigue resistance becomes critical, and therefore, the finishing processes. The surface integrity of a component plays an important role on its fatigue behaviour, as the most common crack initiation area is usually the surface. The present work compares three different mechanical finishing processes that confer better surface properties to the component: polishing, burnishing, and hammer-peening. Each one achieves different degrees of roughness, and residual stress on the surface. The study is not only focused on the resultant mechanical properties, but also in productivity and process robustness. It is concluded that each technology excels in a different property.

The single strain path (SSP) and the reciprocating strain path (RSP) machining are performed on the sample surface with a multi-ball surface burnishing tool to study the effect of different deformation modes on the microstructure. The samples are characterized mechanically and metallographically via a microhardness tester, an optical microscope, and a backscattered scanning electron microscope. The effect of the two strain paths on the plastic strain in the material is explored by developing a numerical simulation model. The characterization and simulation results show that the deformation layer thicknesses are 79 μm, 208 μm, and 290 μm for the SSP treated samples and 108 μm, 191 μm, and 305 μm for the SSP models at penetration depths Dp of 30 μm, 60 μm, and 90 μm, and meantime, 195 μm, 249 μm and, 390 μm for the RSP treated samples and 146 μm, 248 μm, and 396 μm for the RSP models. Moreover, the RSP treated samples are harder than the SSP treated samples at the same penetration depth Dp, attributed to the smaller grain size and longer total length of grain boundaries of the RSP treated samples. The simulation results show that the RSP machining, with the assistance of the Bauschinger effect, further increases the strain degree and the machining influence depth in the sample compared with the SSP machining. The RSP machining disintegrates the dislocation cells in collaboration with the Bausinger effect, which causes the shielding effect of long-range stress to be significantly reduced, further transferring machining stress to the sample interior. It is the main reason why the RSP machining leads to deeper affecting depth. Furthermore, the grain boundaries in the fine-grain layer of the RSP and SSP treated samples are mainly dominated by high angle grain boundaries, supplemented by low angle grain boundaries, with a smaller percentage of twin boundaries, while in the coarse-grain layer are mainly twin boundaries, supplemented by high angle grain boundaries, with a smaller percentage of low angle grain boundaries. The micro-textures of the samples machined by the two strain paths are minor differences, but the grains in the subsurface layers produced different grain rotations.

This paper presents a physics-based model able to simulate the flow stress behavior of the Ti6Al4V alloy during subsequent severe plastic deformation processes, namely turning and burnishing. All the physical and metallurgical mechanisms that accommodate the deformation were considered to describe the material strengthening and they were implemented via user subroutine in a commercial finite element software. Then, the proposed numerical model was used to investigate the effect of combined turning/burnishing processes on the surface integrity of manufactured Ti6Al4V components. Turning and roller burnishing experiments were conducted to validate the proposed finite element model and to analyze the microstructural phenomena and the output variables. The implemented model well fits experimental results, precisely predicting the evolution of grain size, dislocations, hardness, and residual stresses. Different process combinations can lead to similar microstructures and information on different contributions can be highlighted through physics-based modelling and simulated process combinations. Graphical abstract: [Figure not available: see fulltext.]

The application range of magnesium alloys is restricted because of poor tribological performance. The present study focuses on improving the tribological characteristics of magnesium Ze41A alloy by ball burnishing process. The lowest wear rate of 2.997 × (10)−3 mm3/m, CoF of 0.116 and interface temperature of 38 °C are obtained by ball burnishing process. The SEM examination at optimum burnishing condition reveals the oxidative wear mechanism, while the milled surface exhibited plastic deformation mechanism under similar wear conditions. The significant enhancement in tribological performance of magnesium Ze41A alloy is apparently due to the improvement in surface roughness and microhardness during ball burnishing process. The wear rate has been decreased by 51.22%, CoF by 72.58 and interfacial temperature by 39.68% at the optimum burnishing condition as compared to initial milling condition under similar wear conditions. Additionally, the tribological performance is evaluated by fuzzy interface system and the model found to estimate the results with an average absolute error of 4.92%.

With the urgent demand of high-end equipment for high quality surfaces, the technique of ultrasonic vibration-assisted burnishing is introduced to strengthen the surface properties. To explore the influence of the ultrasonic vibration on the dynamic response of a burnishing system, the burnishing friction force generated from a multi-ball surface burnishing system was characterized by chaos theory. The system had four assisted forms: no ultrasonic vibration, one-dimensional (1D) ultrasonic in x-axis, 1D ultrasonic in z-axis, and 2D ultrasonic in xz-axis. The results showed that any burnishing system had chaotic nature. Under the 2D ultrasonic vibration-assisted burnishing, the burnishing friction force was reconstructed to be a chaotic attractor with high convergence degree. Moreover, the burnishing system has notable complexity and stability. The burnished Al7075 alloy sample has an excellent surface with a higher smoothness and hardness. The burnishing with 2D ultrasonic vibration in xz-axis is a technique to enhance surface properties.

The scheme of arrangement of grooves of partially regular microrelief of type II shifted by 0.5 angular pitch is considered. Such grooves are formed by vibration on end faces of rotary bodies. An analytical dependence was obtained to determine the relative area of a partially regular microrelief depending on the geometric parameters of V-shaped grooves. The parameters of the grooves of a partially regular microrelief formed at different distances from the center of rotation are determined, at which the value of the relative area of the partially regular microrelief formed on the treated surface will be stable.

In this paper, the predicted generation mechanism, chatter stability, and characteristics of the unique regenerative chatter with the burnishing process in wiper-turning operations are verified experimentally. It was found in the first part of the paper that the vibration regenerates in the burnishing process by the wiper part of the insert causing a novel type of chatter. In this second part, this chatter phenomenon is investigated in an experimental manner to verify its mechanism. The specific burnishing force, which is a gain factor characterizing the burnishing process, is determined by the Hertzian contact law. In addition, the specific cutting force is measured by a cutting test, the compliance of the flexible structure is measured by a hammering test, and the residual compliance is measured by a static indentation test. Then, experiments are conducted where the tilt angle and the feed rate are varied to find the critical stability. The conducted chatter experiments prove that the predicted generation mechanism, critical stability, and characteristics are true.

The purpose of this paper is to understand the generation mechanism and to propose an analytical model of a unique regenerative chatter with the burnishing process in wiper-turning operations. The authors have found a unique chatter when using wiper inserts, which cannot be explained by the existing chatter theory found in the literature. The authors believe that this occurs because of the burnishing process of the wiper insert, which is the only difference from ordinary turning. At first, the burnishing process, which accompanies wiper inserts, is explained, and the turning operation with this process and the well-known regenerative effect in the cutting process is discussed. Then, the stability of the turning process with the regenerative effects in the cutting and burnishing processes are investigated, and an analytical model is proposed to evaluate the critical stability. Finally, the stability analysis of this unique chatter is conducted, and its generation mechanism and characteristics are examined clearly.

The paper presents the results of the computer modelling of the stressed state and relative density when burnishing a porous hollow cylinder, made from copper sintered powder material. The mathematical model, based on the theory of porous bodies’ plasticity, is used for the analysis. The paper researches the impact of the initial porosity of the material on the effective stresses distribution, relative density and force change when free burnishing of hollow cylinders. It is ascertained that with the decrease of the initial porosity of the sintered material there is the increase of the burnishing force, stresses rate and relative density on the inner sur-face of a hollow cylinder. For porous materials at a certain stage of burnishing, the deformation zone is transformed into the compaction zone with a high relative density which de-creases while moving away from the inner surface of hollow cylinders. The maximum value of the relative density is implemented directly on the inner surface of hollow cylinders; along with this the density value is evenly distributed on the inner wall.

Compressive residual stress is the major aspect in the extension of the fatigue life of aeroengine components. In this study, a modified burnishing surface treatment and conventional shot peening process was used was proposed to improve surface integrity characteristics such as surface finish, hardness, and stable, advantageous compressive residual stress in turned Cylindrical Aluminum 2024Specimen. In burnishing process, a rolling rigid spherical HSS ball is pressed across an Aluminum 2024Specimen under definite fluid pressure generated by the hydraulic unit and also shot peening was carried out at a shot velocity of 300 m/s. This research examined the effect of burnishing treatment and shot peening process on beneficial compressive residual stresses.

Sustainable machining processes are efficiently achieved using the selection of optimal parameters. In this study, the minimum quantity lubrication-assisted multi-roller burnishing (MQLAMRB) operat...

This research investigates the feasibility of improving surface integrity of the Mg-2%Zn alloy via a novel combined process of multidirectional forging (MDF) with ball burnishing technique. Mg-2%Zn alloy was subjected to multidirectional forging up to 5 passes at 280 °C and same sample is ball burnished with depth of press of 0.3 mm, feed of 300 mm/min and force of 250 N for 1 pass. Microstructure (optical and transmission electron microscope), phases (X ray diffraction), roughness (atomic force microscope) and mechanical properties (microhardness and tensile) were analyzed for cast, MDF processed and MDF + ball burnished samples. The study also defines a new reliability simulation framework to predict the roughness and hardness of the MDF + ball burnished samples using Deep Neural Network (DNN) approach. For the analysis, depth of press, feed and number of passes served as inputs for the DNN model. After configuring and training procedure of the model, the predicted roughness and microhardness of the MDF + ball burnished were compared with the results of experimental data. A large increase of microhardness was observed for MDF-5 + BB-1 (5 pass MDF processed Mg-2%Zn alloy + Ball burnished sample), found to be 98 Hv and surface roughness of 306 nm was achieved. According to the results, the obtained R-squared value is very close to the 99.5 percentage from the model for predicting roughness and hardness which is a promising result. Corrosion behavior of the AS-1, MDF-5 and MDF-5 + BB-1 was evaluated in Hank's balanced salt solution. Corrosion rate of the MDF-5 + BB-1 samples were found to be 0.87 mm/y which is 7 times better than that of AS-1 samples (6.10 mm/y). Grain refinement and residual stresses were higher in the MDF-5 + BB-1 sample, which helped significantly to enhance corrosion resistance.

Ball burnishing is a finishing technique involving plastic deformation on the workpiece surface. In this paper, the influence of the ball burnishing operation on the average roughness, tensile properties, anisotropy and work hardening of a TRIP steel was analyzed. An experimental study of the effect of the ball burnishing process on uniaxial tensile specimens was conducted using the Response Surface Methodology (RSM) based on a 32 Factorial Design (FD). The effects of burnishing force (BF) and the number of tool passes (NP) on the average roughness (Ra), the yield stress (σY) and the percentage of elongation to fracture (% El) were evaluated. The quadratic regression models were obtained to predict Ra and σY with determination coefficients (R2) of 0.85 and 0.99, respectively. The results indicated that the ball burnishing process produces a maximum reduction of Ra of 81.7% (from 1.250 to 0.229μm). Also, it was observed that the ductility of the material increased in a 25% and the yield stress and work hardening can be substantially modified. Finally, it was found that by using the ball burnishing process, the planar anisotropy of the sheet can be reduced.

Tangential ultrasonic vibration and vertical ultrasonic vibration are applied in the surface burnishing process (SBP) to study the improvement mechanism of both on the machining performance. The force in the machining process is collected by a Kistler force sensor. The surface roughness (Sa, Sq, Ssk, and Sku) and cross-section hardness of the machined samples are characterized. A molecular dynamic model is established to discuss the acoustic softening effect. Experimental results show that the vertical ultrasonic can reduce the normal force (Fz) value in the machining process. Meanwhile, the tangential ultrasonic vibration can suppress the volatility of the X-axis direction force (Fx) and Y-axis direction force (Fy) while reducing the tangential force (Ft) value. Compared with SBP treated samples, the two-dimensional ultrasonic vibration-assisted surface burnishing process (2D-USBP) can better improve the surface properties of the sample, such as improving the surface roughness, the surface hardness, and the thickness of the strengthening layer. Molecular dynamic results show the introduction of ultrasonic vibration to change the microstructure in the sample. Under the excitation of ultrasonic vibration, the dislocation density and potential energy are increased, and the plastic deformation force is decreased.

Often, surface mechanical treatment (SMT) or heat (quenching, tempering) is used to improve the surface condition and mechanical characteristics such as impact resistance and tensile strength. Hence the objective of this experimental work, where ball burnishing (BB) as well as quenching and tempering were applied on S355 JR steel specimens, is to evaluate the surface hardness Hv, the rupture strength Rm, the energy absorbed W during the impact test, and the work-hardened thickness e after the burnishing operation. Factorial designs were used for the test organization and mathematical models were established for the prediction of Hv, Rm, W, and “e” in function on treatment parameters considered: number of tool passes (i) and the pressure force (Py). The results show that the surface hardness increases by 30.46%. The high levels of Py and i were allowed to improve Rm by 30.8% as well as an increase in tenacity of only 3.6%. Increasing the force to 20kgf promotes mixed rupture under the effect of impact to shock. The quenching and tempering improve the Rupture strength Rm by 183% and 119%, respectively, while the effect of burnishing was limited to a rate of increase of this property of 28% compared to machining.

Cold-drawn metal has a number of undeniable advantages over the hot-rolled one. Increased hardness, high surface quality, stability of the diametrical dimension along the length of the workpiece are the basis for choosing calibrated metal as effective workpieces for the manufacture of long parts such as shafts, axles, and rods. In some cases, such workpieces require a small amount of machining, for example, threading or making necks at the ends of a bar. The wider use of the calibrated metal is hindered by residual stresses that are formed during its manufacture. In the first part of this article, it was proposed to use small plastic deformations to control residual stresses. By the example of a new process of surface plastic deformation, which is called orbital burnishing, the working and residual stresses in cylindrical workpieces are determined. In the second part of the article, the process of enveloping surface plastic deformation is considered, which, at high productivity, makes it possible to reduce the residual tensile stresses in the calibrated metal or form the surface layers of the workpiece compressive stress. A technique for the experimental determination of residual stresses in the volume of a body is based on layer-by-layer removal of the inner and outer layers of cylindrical samples. Influence of the main parameters of the enveloping deformation process on the components of the residual stress tensor is established. A range of relative compressions (0.1 – 1.0 %) is revealed, at which residual compressive stresses are formed in the surface layers of the workpiece. It was found that at a relative compression of 0.5 %, the maximum residual compression stresses are created. Enveloping surface deformation has a positive effect on the residual stress state and on colddrawn metal – the residual tensile stresses can be reduced, removed or converted into compressive ones.

Single point burnishing of low strength alloy with cylindrical shape and small diameter may lead to bending and failure of sample. Thus, there is limitation applying sufficient pressure to the sample that may lead to inappropriate quality characteristics or long time machining due to further pass number. Using hydrostatic pressure through series of face to face roller can be used as potential method for processing of specimens in aforementioned categories. In the present investigation an attempt was made for processing of AA6061-T6 samples which were turned to 8 mm diameter of by multi-roller rotary burnishing process. Experiments were designed and conducted to correlate factors viz burnishing depth, number of rollers, spindle speed and feed rate to surface roughness, surface residual stress and hardness. Analysis of variances have been carried out to check adequacy of developed empirical models and to identify factors with great importance on quality characteristics. Finally, an optimum processing condition was defined by response surface methodology and fatigue life and surface integrity factors of optimum condition were compared with as turned material. The obtained results revealed that feed rate, roller number and spindle speed are factors with great influence on surface roughness, residual stress and hardness respectively. It is also find out that low cycle fatigue life of the sample at optimum level are improved more than three times compared to as turned sample. The outcome of this research can be useful for processing of small size products that need to be surface treated to enhance their properties.

Boosting machining quality is a prominent solution to save production costs for burnishing operations. In this work, a machining condition-based optimization has been performed to decrease surface roughness (SR) and enhance Vickers hardness (VH) of the minimum quantity lubrication-assisted burnishing operation (MQLABO). The burnishing factors are the spindle speed (S), depth of penetration (D), and the air pressure (P). The burnishing trails of the hardened material labeled 40X have been conducted on a milling machine. The adaptive neuro-based-fuzzy inference system (ANFIS) was used to construct the correlations between the process inputs and MQLABO responses. The non-dominated sorting genetic algorithm-II (NSGA-II) is utilized to determine the optimal parameters. The scientific outcomes revealed that the optimal values of the S, D, and P are 800 RPM, 0.09 mm, and 4.0 Bar, respectively. The SR is decreased by 53.8%, while the VH is enhanced by 3.1%, respectively, as coBarred to the initial values.

Cold-drawn metal has a number of undeniable advantages over the hot-rolled one. Increased hardness, high surface quality, stability of the diametrical dimension along the length of the workpiece are the basis for choosing calibrated metal as effective workpieces for the manufacturing of long parts such as shafts, axles, and rods. In some cases, such workpieces require a small amount of machining, for example, threading or making necks at the ends of a bar. The wider use of the calibrated metal is hindered by residual stresses that are formed during its manufacturing. In the first part of this article, it was proposed to use small plastic deformations to control residual stresses. By the example of a new process of surface plastic deformation, which is called orbital burnishing, the working and residual stresses in cylindrical workpieces are determined. In the second part of the article, the process of enveloping surface plastic deformation is considered, which, at high productivity, makes it possible to reduce the residual tensile stresses in the calibrated metal or form the surface layers of the workpiece compressive stress. A technique for the experimental determination of residual stresses in the volume of a body is based on layer-by-layer removal of the inner and outer layers of cylindrical samples. Influence of the main parameters of the enveloping deformation process on the components of the residual stress tensor is established. A range of relative compressions (0.1–1.0%) is revealed, at which residual compressive stresses are formed in the surface layers of the workpiece. It was found that at a relative compression of 0.5%, the maximum residual compression stresses are created. Enveloping surface deformation has a positive effect on the residual stress state and on cold-drawn metal: the residual tensile stresses can be reduced, removed, or converted into compressive ones.

In the present study, the combination of ultrasonic burnishing and heat treatment were applied on a laser cladded Fe-based coating. Besides ultrasonic burnishing at room temperature (UB), two combination strategies of ultrasonic burnishing and heat treatment were explored, i.e. ultrasonic burnishing at a medium temperature (ultrasonic warm burnishing, UWB), and UWB coupled with continuous heat treatment for a period of time (ultrasonic warm burnishing coupled with heat treatment, UWB/HT). Total four samples were prepared and experimentally investigated. Comparing with untreated (control) sample, the surface properties of the three differently treated samples were improved to varying degrees, where the sample subjected to UWB/HT process acquired the best one. UWB/HT Process declined the roughness and porosity of Fe-based coating by 87.86%, 65.41%, and the hardness increased by 34.88% compared to that of control sample, respectively. The residual stress and microstructure of UWB/HT sample also acquired a largest improvement. In addition, the UWB/HT Fe-based coating exhibited the best wear resistance. Summarily, UWB/HT is considered to have the greatest potential to achieve the effective treatment of laser cladding with excellent surface properties over the other two strategies, which is expected to further advance the application of laser cladding technique particularly in the fabrication of some high-demand products serving in harsh conditions.

Surface properties of Astaloy Mo-based steel were enhanced by using DLC deposition. The specimens were formed by double-sided compaction and heated for 30 min at 1393 K, in the NH3 atmosphere. Following this, the plasma nitriding process was applied to improve the adhesion of the DLC coating. Afterward, the DLC coating was performed by Pulsed DC PACVD. Surface characteristics were studied by changing the duty cycle and the Argon/Methane flow ratio. The reciprocating method was carried out to evaluate wear behavior. Field emission scanning electron microscopy equipped with EDS and Raman spectroscopy, hardness tester, nanoindentation test and surface roughness tester were used to evaluate the chemical structure, wear mechanisms of DLC coatings. This study proved that hardness reached up to 12.2 ± 1.11 GPa and the wear behavior was enhanced significantly by the DLC coating deposition. The mass loss increased with a rise in the duty cycle. Increasing the Argon/Methane ratio from 4:1 to 6:1 caused a decrease in the mass loss of DLC coatings. Burnishing, pulling out and adhesive wear were the dominant mechanisms.

The features of the friction process during burnishing of couplings made of the shape memory alloy are considered. The influence of temperatures on the thermomechanical properties of the alloy of the part during burnishing was investigated. The selection of lubricant for burnishing of parts at cryogenic temperatures is analyzed. Keywords: burnishing, nitinol, shape memory effect. albagachiev@yandex.ru, dinara.khasyanova@mail.ru

Improving the surface quality after burnishing operation has been the subject of various published investigations. Unfortunately, the trade-off analysis between the energy consumption and surface characteristics of the internal burnishing has been not addressed due to the expensive cost and huge efforts required. The objective of the present work is to optimize burnishing factors, including the spindle speed, burnishing feed, depth of penetration, and the number of rollers for minimizing the energy consumed in the burnishing time, as well as surface roughness and maximizing Rockwell hardness. An adaptive neuro-based-fuzzy inference system (ANFIS) was used to develop burnishing objectives in terms of machining parameters. The optimization outcomes were selected using an evolution algorithm, specifically the non-dominated sorting particle swarm optimization (NSPSO). The results of the proposed ANFIS models are significant and can be employed to predict response values in industrial applications. The optimization technique comprising the ANFIS and NOPSO is a powerful approach to model burnishing performances and select optimal parameters as compared to the trial and error method as well as operator experience. Finally, the optimal solution can help to achieve the improvements in the energy consumed by 16.3 %, surface roughness by 24.3 %, and Rockwell hardness by 4.0 %, as compared to the common values.

Boosting energy efficiency and machining quality are prominent solutions to achieve sustainable production for burnishing operations. In this work, an effective optimization has been performed to enhance the energy efficiency (EFb) and decrease the machining noise (MN) as well as surface roughness (SR) of the internal burnishing operation. The burnishing factors are the spindle speed (S), burnishing feed (f), burnishing depth (D), and the number of rollers (N). The burnishing trails of the hardened material labeled SCr440 have been conducted on a CNC milling machine. The adaptive neuro-based-fuzzy inference system (ANFIS) was used to construct the correlations between the process inputs and burnishing responses. The entropy approach is employed to calculate the weight of each technical objective. The non-dominated sorting particle swarm optimization (NSPSO) is utilized to determine the optimal parameters. A comprehensive model of the production cost is developed to check the effectiveness of the proposed approach. The scientific outcomes revealed that the optimal values of the S, f, D, and N are 1645 RPM, 260 mm/min, 0.08 mm, and 4, respectively. The improvements in the EFb, SR, and MN are 6.98%, 25.00%, and 2.23%, as compared to the initial values. The machining cost is saved by 6.2% at the optimal solution. Moreover, the scientific finding is a potent technical solution to enhance machining performances for the burnishing process of various components having internal holes.

Burnishing is a finishing manufacturing process that provides the required surface integrity of metal parts. Precise process simulation enables optimization to guarantee the quality of the product. A literature review showed that most researches in this field have used an idealized smooth surface for simulations and have not considered the influence of surface roughness on the simulation results. However, for burnishing processes, the initial roughness has a measurable effect on the simulation quality. Hence, an innovative approach for the preparation of the FEM process model was developed. The approach based on reverse engineering. Using 3D scanning, models of the workpiece and the tool were created and imported in the process model. The developed approach was validated through a case study. The results of the simulation with surface roughness demonstrate a better compatibility to the real process than the results of the same simulation on the idealized surface. Hence, using this approach, it is possible to create a precise model of the process and achieve more qualitative result of the burnishing simulations.

The influence of plastic deformation by ultrasonic burnishing on the surface roughness of Р6М5 and 9ХС steel workpieces with initial surface hardness 57–60 HRC is investigated. A D-optimal Hartley–Kono experiment design is used. The four factors considered are the workpiece’s rotation frequency, the supply, the loading force, and the ultrasound power.

The issues of the process of hardening of parts made from steel 45 by a combined method were considered, which consisted in the application of coating by electric-arc metallization, subsequent lathe work, diamond surface smoothing and pulsed magnetic refinement. Parts that were hardened by a combined method were analyzed for durability. A pilot plant for the study of parts for durability resistance was described. The results of the research are presented. The nature of wearing of the component surfaces hardened by the combined method has been established. According to the test results, it was found that in the process of wear of component surfaces hardened by a combined electromechanical method no run-in occurred. The period of normal exploitation began immediately after the start of the work. The surface of the analyzed part after burnishing deformation by the diamond smoothing method works for a long period of time practically without abrasion. According to this, wear products do not enter the friction zone and cause abrasive wear. The destruction of the surface does not affect the entire surface simultaneously, it occurs in its individual sections. Other sections are only vulnerable to physico-chemical changes. Such partial destruction and changes features of the surface affect the interaction of the conjugate surfaces. Pulsed magnetic refining also increases the wear path by changing the physico-mechanical properties of the original material. The wear stages of coating surfaces hardened by diamond smoothing and pulsed magnetic refinement last longer.

The article presents the results of modeling the process of finishing and hardening cylindrical parts by orbital burnishing. A finite element model of orbital burnishing has been developed using SolidWorks software. The model allows determining some geometric characteristics of a plastic contact patch and a plastic indent, during orbital burnishing depending on the parameters of the working tool. The obtained results show that the most significant influence on the size and area of the plastic indent during orbital burnishing is exerted by the angle of inclination of the working tool and the radius of the orbital rotation, the effect of the working tool radius is less significant. With an increase in the angle of inclination of the working tool from 0 to 60°, its radius from 3 to 11 mm, and the radius of orbital rotation from 2 to 6 mm, the length of the indent increases by 1.3–3.6 times, the width – by 1.1–3.0 times, and the area of the hole by 3.7–10.3 times.

Compressive residual stress is a significant factor in influencing a fatigue failure of a mechanical component. In this perspective, the attempt has been made to induce beneficial compressive residual stress in Ti-6Al-4V alloy by using low plasticity burnishing process. The mechanism of LPB process includes rolling spherical balls made of tungsten carbide material over a material surface under fluid pressure supplied by a hydraulic unit. In this study, the cost-effective low plasticity burnishing tool with hydraulic fluid system is designed and fabricated. The LPB process was carried out on Ti-6Al-4V specimen with a suitable fixture. In this paper, the effect of burnishing process on residual stresses and cold working in Ti-6Al-4V was studied by using burnishing pressure and passes as a process parameter. The explicit module of the FE-Analysis code 6.17 was used with the aim of performing numerical simulation. The obtained experimentation results were considered to validate the results obtained by numerical FE analysis. It was found that there is good agreement between the experimental and numerical results. Both FEM simulation and experimentation results showed that hydraulic burnishing pressure is the most influential parameter in inducing beneficial compressive residual stress with less amount of coldwork.

In this paper, the structure and operational functions of a measurement system, which was installed on a 3-axis CNC lathe for monitoring and optimization of the cutting process are presented. In general, the system records signals of the components of the resultant cutting force, acceleration signals (cutting vibrations) and EFM force signals generated for various machining conditions employed. As a result, the total power consumed was determined. The generated data were archived in the expert system which supports the optimization of the cutting process in terms of various optimization criteria including power/energy consumption.

Burnishing process is considered as the finishing operation to improve surface characteristics of thermal sprayed coatings. The process can be successfully utilized to achieve refined surface layers with ultrafine grains on the surface. The dynamic recrystallization on the surface is achieved due to severe plastic deformation with burnishing process. The decrease in surface roughness and porosity can also be achieved with effectively utilizing the burnishing process. The increase in surface hardness on the surface of coating was due to the compressive residual stresses induced by burnishing operation. The current study reveals the comparative study of burnishing process with different burnishing speeds along with observation of microstructural changes on the surface of thermal spray coatings. The increase in temperature and burnishing forces are also measured to analyze their effect on burnishing properties.

Jelen tanulmányban az élettartam-növelő felületszilárdító eljárások közé tartozó vasalás technológiájának vizsgálatával, az azzal kapcsolatos eredmények bemutatásával foglalkozunk. Analizáljuk, hogy a megmunkálás során beállított paraméterek (vasalási erő, előtolás, sebesség, járatszám) milyen hatással vannak a felületi mikro-keménységre, valamint a feszültségállapotra, illetve elemezzük a köztük lévő korrelációs kapcsolatokat. A kísérletek megtervezése és végrehajtása a teljes faktoriális kísérlettervezés módszerével történik.

High-entropy alloy (HEA) is an emerging alloy which consists of five or more metallic elements with equimolar concentrations and exhibits excellent mechanical properties at cryogenic temperature. However, its machinability is almost unknown. In this study, high frequency one-dimensional ultrasonic vibration-assisted diamond turning (UVDT) experiments were conducted on an FeCrCoMnNi-based HEA to investigate the micro-nanoscale material removal mechanisms. Compared with conventional diamond turning, UVDT produced thinner chips, lower cutting forces, less tool wear and better surface integrity. Due to the ultrasonic vibration-assisted burnishing effect, surface scratches were significantly eliminated. A freeform surface was test-fabricated with optical-level finish.

To improve the mechanical properties of components, low surface plastic deformation caused by low plasticity burning (LPB) process is studied. Multi-objective optimization of process parameters for low plasticity burning on aluminum alloy AA6061T6 has been performed in the present analysis. The burning process parameters are considered for each of four levels such as pressure, speed, ball diameter, ball material, and number of passes. Consideration is given to response parameters such as surface roughness and wear resistance. Experimentation was conducted by considering the Taguchi method design matrix and the orthogonal array L16. In the current research work, multi-objective optimisation was carried out using the Grey Relational Analysis (GRA) technique. The technique is found useful for minimizing roughness of the surface and maximizing wear resistance. After the roughness of the burning surface decreased from 0.688 μm to 0.2593 μm, wear rate also decreased from 4.3076 × 10–3 mm3/Nm to 2.1380 × 10–3 mm3/Nm. The results of the optimization showed that the roughness of the surface decreased by 62%, where the wear rate decreased by 50% compared with the surface turned. The results of multi-objective optimization showed that burnishing pressure and burnishing speed are the important parameters for minimizing surface roughness and maximizing wear resistance.

A kis környezetterhelésű, forgácsnélküli vasalási eljárás javítja a megmunkált felület integritását. A csúszó súrlódásos gyémántvasalása után eredményeződő felületi érdesség és hengerességi hiba elemzését végeztük el. Kutatómunkánk célja annak meghatározása, hogy az EN AW-2011 jelű gyengén ötvözött alumínium anyagú munkadarabok vasalása során az alkalmazott technológiai paraméterek hogyan befolyásolják a felületi érdesség (Ra) és a hengerességi hiba (CYLp, CYLv és CYLt) jellemző értékeit.

In the field of mechanics and biomaterials, particular attention is directed to the finishing step of pieces because it conditions several properties of materials, namely surface quality and microhardness. The mechanical surface treatment (TMS) by burnishing is one among the most competent finishing operations aimed toward improving the characteristics of surface and also the lifetime of components. Although this treatment is extremely effective, but it is very necessary to choose the appropriate combination of process parameters to realize better results. This work aims to improve, by ball burnishing, the microhardness of 316L stainless steel used for the manufacture of biomedical hip prostheses. This property is vital because it directly influences other final properties such as tensile strength, wear resistance and fatigue life. The response surface method based on Box-Behnken model is followed for experiments and an empirical model expressing the relationship between microhardness and process parameters (burnishing force, feed rate, and ball diameter ) is developed. The optimal regime for maximum hardening is also established. The results show that burnishing treatment, carried out on a flat surface, makes it possible to significantly hardening the surface of 316L stainless steel by obtaining a greater value by up to 67% compared to the untreated surface. Scanning electron micrographs show a very thin surface layer containing grains deformed plastically in the burnishing direction.

This study investigates the effects of roller burnishing on the microstructure, surface microhardness, and wear resistance of 316L stainless steel. Experimental design based on the Taguchi orthogonal array was employed to determine the optimized parameter set for maximizing the burnished surface microhardness. Roller burnishing refined the microstructure beneath the surface and improved the microhardness by 45%. Subsequently, results of reciprocating tribological experiments revealed a significant increase in the wear resistance after the burnishing process.

Egy gépelem kifáradás elleni ellenállása annál nagyobb, minél kevesebb makroszerkezeti változást és belső inhomogenitást tartalmaz. Élettartam szempontjából meghatározó továbbá a kedvező a feszültségállapot és a kisebb felületi érdessége is. Publikációnk az érdességet hatékonyan csökkentő vasalási megmunkálás során beállított erő átlagos felületi érdességre gyakorolt hatásával, illetve annak végeselemes modellezésével foglalkozik. A folyamat szimulációja DEFORM-2D szoftver alkalmazásával készül, megfelelve a gyakorlatban megvalósított vasalási paraméterek (vasalási erő, előtolás, sebessé) számszerű értékeinek is, ezáltal lehetővé téve egy összehasonlító elemzést gyengén ötvözött alumínium anyagminőség esetén.

Slide burnishing process, which is a surface severe plastic deformation technique, offers an attractive post-machining alternative due to its chip-less and relatively simple operations. The purpose of the present work is to investigate effects of initial turned surface roughness on the burnished surface roughness and hardness in slide burnishing. The carbon steel samples those have different roughness surfaces being treated were prepared by turning by varying the feed. Slide burnishing was then carried out by a silicon nitride ceramic ball that was loaded and fed on the turned surface of a rotating specimen using a lathe machine. It was found that the turned surfaces were smoothed drastically by the burnishing process, and that the Ra and Rz values were reduced at most by a factor of 52 and 21, respectively. However, the smoothing effect of burnishing has limit, and the limited maximum height roughness (Rz*) for burnishing smoothing increased under a higher burnishing force and with a larger ball diameter. When the Rz values of initial turned surfaces were less than the Rz*, the roughness of the burnished surfaces did not depend on the roughness of the initial turned surface and the burnishing force. There was no significant difference in the burnished microstructure and hardness under a specific burnishing force among the initial turned surface roughness, while a higher burnishing force caused a greater increase in surface hardness.

Spinning process is a sheet metal forming technology used in the production of the symmetrical industrial parts. It is an efficient and inexpensive manufacturing process and has been widely used in various applications. In this research, new technique was developed to perform three different operations in the same stroke, namely conventional spinning, shear spinning (wall thickness reduction) and burnishing processes. This new technique has been performed by a new tool which consists of three stages, the first stage consists of two rollers to carry out conventional spinning process; the second stage includes two opposite balls to perform the process of shear spinning and the last stage comprises another two opposite balls to perform the process of burnishing. The burnishing balls differ from the shear balls in which that the burnishing balls have a spring behind the balls to decide the required burnishing load. Experimental work was conducted and confirmed the success of the presented technique. The response of the product quality and required load to process parameters such as rotational speed (46,76,150 and 230 rpm), axial feed (0.15,0.3,0.6 and 1.21 mm/rev) and burnishing load (20, 25 and 30 KN) was checked and clarified. The results showed that, the optimum condition for forming load occurred at rotation speed at 150 rpm, axial feed 0.3 rev/mm and burnishing load 25 KN.

The BTA (Boring and Trepanning Association) deep-hole drilling process is used to machine bores with large diameters (D > 40 mm) and a bore-length (l) to diameter ratio lager than ten (l/D >10). The resulting bore surface and its sub-surface zone are influenced by the cutting action and the self-guiding effect of the tool. The Guide pads support the asymmetric tool on the bore surface while burnishing the surface. The mechanical/thermal loads induced by the process lead to hardening, microstructure alteration and substantial residual stresses in the sub-surface. Particularly the residual stress state influences the fatigue strength and reliability of the machined part. To predict the residual stress in BTA deep-hole drilling, for the first time a novel analytical modeling approach is developed based on eigenstrain theory, integrating the machining process of cutting insert and the burnishing process of guide pad. A semi-analytical 3D contact model is built for the cycling incremental plasticity due to the equivalent mechanical/thermal loading of cutting process. Furthermore, an approximate estimation is provided for the contact condition between the inclined guide pad and bore hole, which facilitates the incremental contact analysis in the burnishing process. With the induced inelastic deformation known, residual stress distribution in the machined surface is constructed based on the eigenstrain theory. The results of the model are compared to X-Ray-Diffraction (XRD) measurements of BTA deep-hole drilled specimens.