Analytical modeling of surface generation in ultrasonic ball burnishing including effects of indentation pile-up/sink-in
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(2020) 20:144
ORIGINAL ARTICLE
Analytical modeling of surface generation in ultrasonic ball burnishing including effects of indentation pile‑up/sink‑in and chipping fracture Reza Teimouri1,2 · Zhanqiang Liu1,2 · Bing Wang3 Received: 11 August 2020 / Revised: 27 October 2020 / Accepted: 2 November 2020 © Wroclaw University of Science and Technology 2020
Abstract In mechanical based machining processes, the surface topography is generated through series of hierarchical pattern. Plastic deformation as result of contact and kinematic of motion are two main factors which determine evolution of surface generation. To basically optimize the surface quality, accurate predictive model of surface generation and constraints are required. In the present work, analytical models of dimple formation and hierarchical surface generation in ultrasonic assisted ball burnishing process are proposed. Pile-up and sink-in as two phenomena of indentation during both of loading and unloading phases were taken into the developed models. Considering interaction of indentation profile and kinematic of motion, three-dimensional surface topography and surface roughness are also analytically predicted. A criterion for surface failure is defined to perform process without any erosion. Confirmation of results have been made by series of single trace and multitraces burnishing experiments on AA6061-T6 and AISI 1045. The results of indention profile, surface topography, roughness and failure criterion which were derived from predictive models were completely consistent with confirmatory experiments. Keywords Burnishing · Surface topography · Hierarchical pattern · Failure criterion
1 Introduction Burnishing process is usually used as a final operation to enhance the surface integrity of machined components such as surface roughness, microstructure, hardness and residual stress. It has been proved that burnishing can significantly improve both the surface roughness and residual stress of the as-turned surfaces [1]. Surface topography is formally known as one of most important evaluation indicators of burnishing process as it deeply influences the fatigue life. The ability to precisely
* Zhanqiang Liu [email protected] 1
School of Mechanical Engineering, Shandong University, Jingshi Road 17923, Jinan 250061, People’s Republic of China
2
Key National Demonstration Center for Experimental Mechanical Engineering Education/Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MQE, Jinan, People’s Republic of China
3
Manufacturing Institute, Georgia Institute of Technology, Atlanta, GA 30332, USA
predict the machining surface roughness is very helpful in reducing the cost and improving productivity. According to the research reported in current literatures, mathematical methods for evaluation of surface profile can be divided into empirical and analytical predictive models. In empirical methods, the surface roughness model is developed through series of statistical methods, e.g. response surface methodology in statistic
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