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Slide burnishing versus deep rolling—a comparative analysis

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Abstract

This article presents outcomes from a comparative analysis involving three static burnishing processes: slide burnishing (SB), roller burnishing (RB), and deep rolling (DR). The treated material was 41Cr4 steel. The investigative methods used were fully coupled thermal-stress finite element (FE) simulations and natural experiments. Using one and the same magnitudes for the governing factors, the basic difference among the compared processes was the type of contact between the deforming element and the surface being burnished—sliding friction for SB and rolling contact for RB and DR. SB was implemented with a spherical-ended polycrystalline diamond whereas RB and DR were conducted using a single toroidal roller with the same magnitude for the radius of the toroid surface as that for the radius of the deforming diamond. The objects of comparison were in themselves processes and considered to be alterations in the thermodynamic systems’ states, as were the obtained surface integrities (SIs) of the treated specimens and their fatigue behaviors. It was established that three-quarters of the external work in SB converts into heat in the “deforming element–workpiece” contact area, which leads to the so-called softening effect in the surface layers. The comparison of the energy balances of the investigated processes clearly demonstrates the thermo-mechanical nature of the SB process, whereas the deforming processes in the RB and DR can be assumed to be purely mechanical. On the other hand, SB provides less roughness, significantly greater micro-hardness, larger-in-absolute-values compressive residual stresses, a more refined microstructure and, as a result, greater fatigue strength compared with RB and DR.

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Abbreviations

A 5 :

Elongation

b :

Material parameter

C :

Initial kinematic hardening modulus

d :

Outer diameter of toroidal roller

dA :

Useful resistance

\( \mathrm{d}{\overline{\mathrm{A}}}^{\mathrm{e}} \) :

Elementary external work

\( d{\mathrm{A}}_{\mathrm{Q}}^{\mathrm{e}} \) :

Elementary work, converted into a heat

dAm :

Elementary mass forces work

dAel :

Elementary work for elastic deformation

dApl :

Elementary work for plastic deformation

dAlost :

Loss of the available elementary work

dEk :

Change in the system kinetic energy

dQe :

Elementary heat from external source

dψ :

Dissipated energy

E :

Young’s modulus

f :

Burnishing feed rate

f c :

Cutting feed rate

F0 :

Contact area

F b :

Burnishing force

k :

Conductivity of the gap between two surfaces

K ij :

Stiffness submatrices

Q ∞ :

Material parameter

N i :

Number of cycles to failure

pn, i :

Surface load

q g :

Generated heat flux density

r :

Diamond insert radius

R :

Asymmetry coefficient

\( {R}_a^{init} \) :

Initial surface roughness

R a :

Surface roughness

R T :

Thermal residual vectors

R u :

Mechanical residual vectors

Δs :

Increments of the slip

s i :

X-ray elastic constants

Sgen :

Entropy generated

Δu :

Corrections of the incremental displacement

Δt :

Increments of the time

T :

Temperature

Ta :

Absolute temperature

ΔT :

Corrections of the incremental temperature

v :

Burnishing velocity

V :

Volume of the workpiece affected layers

α ij :

Back stress tensor

α t :

Coefficient of thermal expansion

γ :

Material constant

ϕ i :

Coefficients

\( {\overline{\varepsilon}}^{pl} \) :

Equivalent plastic strain

μ :

Friction coefficient

ν :

Poisson’s ratio

η :

Coefficient

ρ :

Density

σ ij :

Stress tensor

σ u :

Ultimate stress

σ|0 :

Yield limit

σ 0 :

Equivalent stress

τ :

Stress from friction,

ξ ij :

Strain velocity tensor

ψ :

Transverse contraction

BB:

Ball burnishing

DB:

Diamond burnishing

DR:

Deep rolling

EPS:

Equivalent plastic strain

FE:

Finite element

FEM:

Finite element method

MST:

Mechanical surface treatment

RB:

Roller burnishing

SB:

Slide burnishing

SDB:

Slide diamond burnishing

SI:

Surface integrity

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Acknowledgments

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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Authors and Affiliations

  1. Department of Applied Mechanics, Technical University of Gabrovo, 5300, Gabrovo, Bulgaria

    J. T. Maximov, G. V. Duncheva, A. P. Anchev & V. P. Dunchev

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  1. J. T. Maximov
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  2. G. V. Duncheva
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  3. A. P. Anchev
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  4. V. P. Dunchev
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Correspondence to J. T. Maximov.

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Maximov, J.T., Duncheva, G.V., Anchev, A.P. et al. Slide burnishing versus deep rolling—a comparative analysis. Int J Adv Manuf Technol 110, 1923–1939 (2020). https://doi.org/10.1007/s00170-020-05950-2

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