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Open AccessArticle

Finite Element Analysis of Ball Burnishing on Ball-End Milled Surfaces Considering Their Original Topology and Residual Stress

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Mechanical Engineering Department, University of Tabriz, 29 Bahman Blvd 5138855471, Tabriz 51368, Iran
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Department of Engineering, Faculty of Science and Technology, Universitat de Vic · Universitat Central de Catalunya, C. de la Laura 13, 08500 Vic, Spain
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Department of Mechanical Engineering, Universitat Politècnica de Catalunya, Av. Eduard Maristany 10–14, 08019 Barcelona, Spain
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Department of Science and Material Engineering, Universitat Politècnica de Catalunya, Av. Eduard Maristany 10–14, 08019 Barcelona, Spain
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Department of Mechanical and Manufacturing Engineering, Universidad de Sevilla, C. de los Descubirmientos s/n, 41092 Sevilla, Spain
*
Author to whom correspondence should be addressed.
Metals 2020, 10(5), 638; https://doi.org/10.3390/met10050638
Received: 20 April 2020 / Revised: 7 May 2020 / Accepted: 12 May 2020 / Published: 14 May 2020
(This article belongs to the Special Issue State-of-Art within 3D Printing and Advanced Machining Processes)
Ball burnishing is a superfinishing operation whose objective is the enhancement of surface integrity of previously machined surfaces, hence its appropriateness to complement chip removal processes at the end of a production line. As a complex process involving plastic deformation, friction and three-dimensional interaction between solids, numerical solutions and finite element models have typically included a considerable amount of simplifications that represent the process partially. The aim of this paper is to develop a 3D numerical finite element model of the ball burnishing process including in the target workpiece real surface integrity descriptors resulting from a ball-end milled AISI 1038 surface. Specifically, its periodical topological features are used to generate the surface geometry and the residual stress tensor measured on a real workpiece is embedded in the target surface. Secondly, different models varying the effect of the coefficient of friction and the direction of application of burnishing passes with regards to the original milling direction are calculated. Results show that the resulting topology and residual stresses are independent of the burnishing direction. However, it is evident that the model outputs are highly influenced by the value of the coefficient of friction. A value of 0.15 should be implemented in order to obtain representative results through finite element models. View Full-Text
Keywords: ball burnishing; FEM; residual stress; topology; steel ball burnishing; FEM; residual stress; topology; steel
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Amini, C.; Jerez-Mesa, R.; Travieso-Rodriguez, J.A.; Llumà, J.; Estevez-Urra, A. Finite Element Analysis of Ball Burnishing on Ball-End Milled Surfaces Considering Their Original Topology and Residual Stress. Metals 2020, 10, 638.

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