Isotropic finishing of austempered iron casting cylindrical parts by roller burnishing
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ORIGINAL ARTICLE
Isotropic finishing of austempered iron casting cylindrical parts by roller burnishing A. Rodriguez 1 & L. N. López de Lacalle 1 & O. Pereira 1 & A. Fernandez 1 & I. Ayesta 1 Received: 14 May 2020 / Accepted: 9 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Roller burnishing technique to achieve isotropic surface topography on cylindrical components made of austempered ductile iron (ADI) casting is presented in this paper. In the last years, ADI casting components are used in many mechanical applications, due to their enhanced mechanical properties. ADI castings are difficult-to-cut materials; therefore, advanced techniques to improve manufacturing productivity are necessary and under research. On the other hand, spiral roughness pattern produced by turning operation is a common source of unconformities in several applications. Turning produces a defined kinematic pattern, similar to a thread. This work presents a theoretical and experimental validation using different burnishing conditions. Roughness and surface topography and surface integrity were checked. Results show that the technique greatly improves surface roughness, and eliminates the kinematic-driven roughness pattern of turning, leading to a more isotropic finishing. A comparison between roller burnishing and ball burnishing is also presented in this paper. Keywords Roller burnishing, . Austempered ductile iron, . ADI isotropic finishing, . Surface integrity, . Topography
1 Introduction The combination of novel materials and advanced manufacturing processes is key in many manufacturing sectors such as aeronautics, automotive, gear industry, heavy duty equipment, etc. In this work, the use of a novel cross-hatch type technique using conventional roller burnishing tools applied on austempered ductile iron (ADI) casting components is presented. Some relevant research results were presented by authors previously in [1] about burnishing of rotary components. Moreover, the elimination of surface profile generated after turning brake disks was also analyzed by authors Highlights • A novel procedure to get surface topography with cross-hatch patterns is presented using the roller burnishing technique. • A proposed finishing operation is developed for ADI materials. • Burnishing parameters and their influence are analyzed for cylindrical components. • Isotropic and no-directional pattern is obtained after turning * L. N. López de Lacalle [email protected] 1
Aeronautics Advanced Manufacturing Center (CFAA), University of the Basque Country (UPV/EHU), Parque Tecnológico de Zamudio 202, 48170 Bilbao, Spain
applying abrasive brushes [2]. Turning operation always induces a kinematically defined pattern, with spirals on part surfaces or thread-like profiles. Spiral/thread patterns can bring up many problems, such as leakage of oil in sealed zones in gearboxes, vibrations in brakes, and many others. In some applications, manufacturing requirements forbid turning due to this drawback. In the field of cast
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