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### Modeling of surface geometric structure state after intergrated formed milling and burnishing

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Warianty tytułu
PL
Modelowanie stanu struktury geometrycznej powierzchni po zintegrowaniu kształtującego frezowania z wykończeniowym nagniataniem
Języki publikacji
EN
Abstrakty
EN
The article deals with computer-based modeling of burnishing a surface previously milled with a spherical cutter. This method of milling leaves traces, mainly asperities caused by the cutting crossfeed and cutter diameter. The burnishing process – surface plastic treatment – is accompanied by phenomena that take place right in the burnishing ballmilled surface contact zone. The authors present the method for preparing a finite element model and the methodology of tests for the assessment of height parameters of a surface geometrical structure (SGS). In the physical model the workpieces had a cuboidal shape and these dimensions: (width × height × length) 2×1×4.5 mm. As in the process of burnishing a cuboidal workpiece is affected by plastic deformations, the nonlinearities of the milled item were taken into account. The physical model of the process assumed that the burnishing ball would be rolled perpendicularly to milling cutter linear traces. The model tests included the application of three different burnishing forces: 250 N, 500 N and 1000 N. The process modeling featured the contact and pressing of a ball into the workpiece surface till the desired force was attained, then the burnishing ball was rolled along the surface section of 2 mm, and the burnishing force was gradually reduced till the ball left the contact zone. While rolling, the burnishing ball turned by a 23° angle. The cumulative diagrams depict plastic deformations of the modeled surfaces after milling and burnishing with defined force values. The roughness of idealized milled surface was calculated for the physical model under consideration, i.e. in an elementary section between profile peaks spaced at intervals of crossfeed passes, where the milling feed fwm = 0.5 mm. Also, asperities after burnishing were calculated for the same section. The differences of the obtained values fall below 20% of mean values recorded during empirical experiments. The adopted simplification in aftermilling SGS modeling enables substantial acceleration of the computing process. There is a visible reduction of the Ra parameter value for milled and burnished surfaces as the burnishing force rises. The tests determined an optimal burnishing force at a level of 500 N (lowest Ra = 0.24 μm). Further increase in the value of burnishing force turned out not to affect the surface roughness, which is consistent with the results obtained from experimental studies.
PL
Słowa kluczowe
EN
PL
Wydawca
Rocznik
Tom
Strony
131--136
Opis fizyczny
Bibliogr. 13 poz., rys., tab.
Twórcy
autor
• West Pomeranian University of Technology Faculty of Mechanical Engineering and Mechatronics Aleja Piastów 19, 70-310 Szczecin, POLAND
autor
• West Pomeranian University of Technology Faculty of Mechanical Engineering and Mechatronics Aleja Piastów 19, 70-310 Szczecin, POLAND
autor
• Maritime University of Szczecin Faculty of Marine Engineering ul. Wały Chrobrego 1-2, 70-500 Szczecin, POLAND
Bibliografia
• [1] C.H. Chen and F.J. Shiou. “Determination of Optimal Ball-Burnishing Parameters for Plastic injection Moulding Steel”, International Journal of Advanced Manufacturing Technology, vol. 21, issue 3, March 2003, pp. 177-185.
• [2] D. Grochała, S. Berczyński and Z. Grządziel. “Stress in the surface layer of objects burnished after milling”, International Journal of Advanced Manufacturing Technology, vol. 72, issue 9, June 2014, pp. 1655- 1663.
• [3] R. Gubała, D. Grochała and W. Olszak. „Mikrohydrauliczne narzędzie do nagniatania złożonych powierzchni przestrzennych”, Mechanik, no. 1, 2014, pp. 22-23.
• [4] J. Kalisz, K. Żak, W. Grzesik and K. Czechowski. „Characteristics of surface topography after rolling burnishing of EM AW-AlCu4MgSi(A) aluminum alloy”, Journal of Machine Engineering, vol. 15, no. 1, 2015, pp. 71-80.
• [5] W. Kwaczyński, K. Chmielewski and D. Grochała. „Programowanie frezowania i nagniatania złożonych powierzchni przestrzennych na centrach frezarskich ze sterowaniem wieloosiowym”, in Współczesne problemy technologii obróbki przez nagniatanie, vol. 3, W. Przybylski, Ed., Gdańsk: Politechnika Gdańska, Wydział Mechaniczny, 2011, pp. 179-191.
• [6] L.N. López de Lacalle, A. Lamikiz, J. Muñoa and J.A. Sánchez. “Quality improvement of ball-end milled sculptured surfaces by ball burnishing”, International Journal of Machine Tools & Manufacture, vol. 45, issue 15, December 2005, pp. 1659-1668.
• [7] L.N. López de Lacalle, A. Lamikiz, J.A. Sánchez and J.L. Arana. “The effect of ball burnishing on heat-treated steel and Inconel 718 milled surfaces”, International Journal of Advanced Manufacturing Technology, vol. 32, issue 9-10, April 2007, pp. 958-968.
• [8] A. Rodríguez, L.N. López de Lacalle, A. Celaya, A. Lamikiz and J. Albizuri. “Surface improvement of shafts by the deep ball-burnishing technique”, Surface & Coatings Technology, vol. 206, 2012, pp. 2817-2824.
• [9] F.J. Shiou and C.H. Chen. “Ultra-precision surface finish of NAK80 mould tool steel using sequential ball burnishing and ball polishing processes”, Journal of Materials Processing Technology, vol. 201, 2008, pp. 554-559.
• [10] F.J. Shiou and C.H. Chuang. “Precision surface finish of the mold steel PDS5 using an innovative ball burnishing tool embedded with a load cell”, Precision Engineering, vol. 34, issue 1, January 2010, pp. 76-84.
• [11] M. Sosnowski and D. Grochała. „Problemy technologii nagniatania powierzchni przestrzennych złożonych na centrach obróbkowych”, Mechanik, no. 1, 2011, pp. 14-18.
• [12] V.P. Kuznetsov, LYu. Smolin, A.J. Dmitrtev, S.Yu. Tarasov, V.G. Gorgots. "Toward control of subsurface strain accumulation in nanostructurin burnishin on hermostrenghened steel”. Surface&Coatings Technol. No. 285 2016, s. 171-178., http://dx.doi.org/10.1016/j.surfcoat.2015.11.045K.
• [13] Żak and W. Grzesik. “Investigation of technological effects of ball burnishing after cryogenic turning of hard steel”, Advances in Manufacturing Science and Technology, vol. 38, no. 1, 2014, pp. 37-52.
Uwagi
PL
Opracowanie ze środków MNiSW w ramach umowy 812/P-DUN/2016 na działalność upowszechniającą naukę (zadania 2017)
Typ dokumentu
Bibliografia