Surface Integrity of AISI 52100 Bearing Steel after Robot-Based Machine Hammer Peening
Abstract
:1. Introduction
1.1. Initial Situation and Motivation
1.2. Objective
1.3. Approach
2. Materials and Methods
2.1. Analysis of Robot Dynamics
2.2. MHP Test Bench Environment and Characterisation Methods
3. Results and Discussion
3.1. Robot Acceleration
3.2. Robot Vibration and Indentation Profiles during MHP
3.3. Surface Roughness
3.4. Surface Layer Hardness
3.5. Residual Stresses
3.6. Grain Size
4. Conclusions
- Independent of the selected feed rate of the industrial robot, the range of constant feed rate and thus reproducible MHP conditions can be described mathematically.
- Because of the high robot stiffness (eigenfrequency fr = 42.5 Hz), the lateral deviation during MHP processing along a hammering path and along the impact axis are very small. Therefore, this robot enables reproducible MHP processing with regard to a defined energy density.
- Depending on the contact energy and energy density, the electrodynamic MHP can not only smoothen but also roughen the surface. A reduction of the roughness Sz by 60% compared to a milled surface can be achieved. A large hammer head diameter and a small stroke tend to be advantageous.
- The surface hardness can be increased by 75% in the considered MHP parameter range and an effective depth of hardening of z = 1500 µm can be achieved. A high plunger stroke and a small hammer head diameter are particularly advantageous.
- High compressive residual stress maxima σx,max = −950…−580 MPa were introduced below the surface. A small hammer head diameter and high stroke tend to lead to higher compressive residual stress maxima.
- A significant grain size reduction down to the submicron range could be achieved down to a surface layer depth z = 150 µm.
Author Contributions
Funding
Conflicts of Interest
References
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C | Si | Mn | P | S | Cr | Mo | Al | Cu | |
---|---|---|---|---|---|---|---|---|---|
wt% | 0.955 | 0.251 | 0.391 | 0.012 | 0.005 | 1.510 | 0.015 | 0.028 | 0.141 |
σ (wt%) | 0.019 | 0.001 | 0.003 | <0.001 | <0.001 | 0.008 | <0.001 | 0.003 | <0.001 |
Test Series | |||||||||
---|---|---|---|---|---|---|---|---|---|
No. | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 |
a (mm) | 0.05 | ||||||||
f (Hz) | 120 | ||||||||
d (mm) | 6 | 10 | 12 | ||||||
h (mm) | 0.1 | 0.3 | 0.5 | 0.1 | 0.3 | 0.5 | 0.1 | 0.3 | 0.5 |
Ec (mJ) | 7 | 20 | 40 | 7 | 20 | 40 | 7 | 20 | 40 |
w (mJ/mm2) | 2800 | 8000 | 16,000 | 2800 | 8000 | 16,000 | 2800 | 8000 | 16,000 |
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Mannens, R.; Uhlmann, L.; Lambers, F.; Feuerhack, A.; Bergs, T. Surface Integrity of AISI 52100 Bearing Steel after Robot-Based Machine Hammer Peening. J. Manuf. Mater. Process. 2020, 4, 61. https://doi.org/10.3390/jmmp4020061
Mannens R, Uhlmann L, Lambers F, Feuerhack A, Bergs T. Surface Integrity of AISI 52100 Bearing Steel after Robot-Based Machine Hammer Peening. Journal of Manufacturing and Materials Processing. 2020; 4(2):61. https://doi.org/10.3390/jmmp4020061
Chicago/Turabian StyleMannens, Robby, Lars Uhlmann, Felix Lambers, Andreas Feuerhack, and Thomas Bergs. 2020. "Surface Integrity of AISI 52100 Bearing Steel after Robot-Based Machine Hammer Peening" Journal of Manufacturing and Materials Processing 4, no. 2: 61. https://doi.org/10.3390/jmmp4020061