Effect of Ball Burnishing Pressure on Surface Roughness by Low Plasticity Burnishing Inconel 718 Pre-Turned Surface
2. Theoretical Modeling of Low Plasticity Burnished Surface Roughness
2.1. Surface Formation Mechanism of LPB
- The turned surface roughness peaks are simplified to wedge shapes.
- The roller is simplified as a line since the diameter of the roller is much larger than the surface roughness peak.
- The plastic deformation of the surface wedge is larger compared to that of the elastic deformation. Therefore, the material of the surface roughness peak is assumed as the ideal rigid-plastic material and the roller rigid body.
- The frictional coefficient between the ball and the workpiece is 10−5~5 × 10−3 . Therefore, the surface is assumed to be frictionless to simplify the model derivation.
- The surface is flat when the surface roughness reaches the minimum value.
- The low boundary of surface roughness is not affected by the pile-up.
2.2. Modeling of Surface Roughness in SS
2.3. Modeling of Surface Roughness in IS
2.4. Validation of Proposed Model Prediction Results
3.2. Experimental Method
4. Results and Discussion
4.1. Experimental Results
4.2. Surface Roughness Prediction and the LPB Pressure Optimization for LPBed Inconel 718
- The analytical prediction model for the LPBed surface roughness was proposed based on Hertz contact mechanics and slip-line field theory. The increment of the surface roughness in IS was attributed to the pile-up. Considering the deterioration, the proposed model could successfully predict surface roughness under excessive pressures.
- The LPBed surface roughness of AISI 1042 was used to validate the proposed model. The predicted result of the minimum roughness was 2.512 μm (the error was 0.8%). Moreover, the surface roughness at 10.4 MPa was 3.413 μm (13.3%). According to the proposed model, the optimal LPB pressure corresponding to the minimum surface roughness was 4.8 MPa (25%). The results of Li’s model were 2.104 μm (15.5%), 2.104 μm (30.1%) and [4.8 MPa, +∞) (+∞%), respectively. Considering the pile-up, the proposed model could predict the surface roughness and the optimal pressures more accurately compared with the model of Li.
- The Inconel 718 was manufactured under different LPB pressures. The tool marks could be smoothed out by the LPB process. The minimum value of surface roughness was 1.079 μm. The surface roughness decreased by 72.9% compared with the turned surface roughness. However, the minimum surface roughness was limited. The surface roughness increased by 12.8% when the pressure reached 21 MPa. Pile-up and indentations observed under excessive pressures supported the deterioration of the surface roughness.
- The proposed model was used to predict the surface roughness and the optimal interval of the LPB pressure. The error in the proposed results was less than 7%. The proposed model was more accurate than Li’s model (15.3%). The predicted optimal interval (12.2 MPa to 17.5 MPa) was consistent with the experimental one (12 MPa to 18 MPa). The proposed model could be used to predict the LPBed surface roughness of Inconel 718, and further conduct the LPB process.
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
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|Material||E (GPa)||ν||σs (MPa)||σb (MPa)||Ry0 (μm)||α (°)||Rball (mm)|
|Material||E (GPa)||ν||σs (MPa)||σb (MPa)|
|Results||Ry,min (μm)||ERmin||Ry,21 (μm)||ER21||Emax||IOP (MPa)|
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Cui, P.; Liu, Z.; Yao, X.; Cai, Y. Effect of Ball Burnishing Pressure on Surface Roughness by Low Plasticity Burnishing Inconel 718 Pre-Turned Surface. Materials 2022, 15, 8067. https://doi.org/10.3390/ma15228067
Cui P, Liu Z, Yao X, Cai Y. Effect of Ball Burnishing Pressure on Surface Roughness by Low Plasticity Burnishing Inconel 718 Pre-Turned Surface. Materials. 2022; 15(22):8067. https://doi.org/10.3390/ma15228067Chicago/Turabian Style
Cui, Pengcheng, Zhanqiang Liu, Xinglin Yao, and Yukui Cai. 2022. "Effect of Ball Burnishing Pressure on Surface Roughness by Low Plasticity Burnishing Inconel 718 Pre-Turned Surface" Materials 15, no. 22: 8067. https://doi.org/10.3390/ma15228067