Effect of turning-induced initial roughness level on surface roughness and residual stress improvements in subsequent bu
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(2020) 20:80
ORIGINAL ARTICLE
Effect of turning‑induced initial roughness level on surface roughness and residual stress improvements in subsequent burnishing Peirong Zhang1 · Jin Du1 · Hui Zhang1 · Guosheng Su1 · Xuehui Shen1 · Weimin Huang2 · Zhanqiang Liu3 Received: 30 January 2020 / Revised: 18 May 2020 / Accepted: 10 June 2020 © Wroclaw University of Science and Technology 2020
Abstract The hydraulic support column of comprehensive mining equipment is the most important part, subjecting to corrosion, wear and collision. The scrapped columns are restored by laser cladding to replace plating process for enhancing service life. All that is required after laser cladding is subtractive machining to improve the surface quality of the laser cladded coatings. This work focused on the remanufacturing machining strategy for re-contouring the laser cladding restored columns. First, surface roughness model of the laser cladded coatings by turn-burnishing was presented based on the surface generation mechanism. Then the effect of turning-induced roughness level on the surface roughness improvements by subsequent burnishing is addressed. Results indicated that the reduction of surface roughness by burnishing showed positive correlation with the feed in initial turning with conventional inserts, while was negatively correlated with the feed in initial turning with wiper inserts. In addition, the initial turning-induced surface roughness level generated great influence on the residual stress improvement in subsequent burnishing. Based on the findings, proper remanufacturing machining strategies for re-contouring the laser cladding-restored hydraulic support columns were presented. Keywords Remanufacturing · Laser cladding · Burnishing · Surface roughness · Residual stress
1 Introduction 1.1 Research motivation Laser cladding has been commonly utilized for remanufacturing key parts with high values. The durability and strength of the remanufactured parts by laser cladding are improved and, as a result, service life is extended when compared to the electroplating process [1]. The energy consumption and emissions are quantitatively estimated by laser cladding * Peirong Zhang [email protected] 1
School of Mechanical and Automotive Engineering, Qilu University of Technology (Shandong Academy of Sciences), Jinan 250353, People’s Republic of China
2
Shandong Province Key Laboratory of Mine Mechanical Engineering, Shandong University of Science and Technology, Qingdao 266590, People’s Republic of China
3
Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE, School of Mechanical Engineering, Shandong University, Jinan 250061, People’s Republic of China
[2]. In addition, the surfaces can be updated by laser cladding to resist wear, corrosion and/or fatigue. Liu et al. [3] showed that the corrosion current of 45 steel can be reduced by orders of magnitude by laser cladding with Ni60CuMoW alloy powder. Xu et al. [4] also showed that both the wear and corrosion resistance of 45 steel can b
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