buletin ŞtiinŢific, seria c, fascicola: mecanică ... · buletin ŞtiinŢific, seria c,...

BULETIN ŞTIINŢIFIC, Seria C, Fascicola: Mecanică, Tribologie, Tehnologia Construcţiilor de Maşini

SCIENTIFIC BULLETIN, Serie C, Fascicle: Mechanics, Tribology, Machine Manufacturing Technology ISSN 1224-3264, Volume 2015 No.XXIX

94

Examination of Surface Roughness of Burnished Workpieces

Gyula VARGA1, * - Ferenc SZIGETI

2 - Gergely DEZSŐ

2

Abstract: This study deals with the process of diamond burnishing. It contains with the examination of the effect of

technological parameters of burnishing on the surface roughness of the burnished surface. A new dimensionless

parameter, the improvement ratio of surface roughness, was determined for the evaluation of the effectiveness and

goodness of the sliding burnishing process. Applied burnishing parameters were: burnishing speed, burnishing feed,

and burnishing force. By the use of Factorial Experimental Design new empirical formula was determined for the

improvement ratio of surface roughness which is valid in between the minimal and maximum parameters of the input

parameters. Graphical demonstration and the evaluation of the measuring results closes the paper.

Keywords: Burnishing, factorial experiment design, surface roughness, burnishing force

1 INTRODUCTION

An innovative cutting manufacturing process

integrates aspects such as industrial safety and efficient

use of operating aids apart from the productivity and

quality. Crucial factors of influence concerning this

problem are

- the efficient lubricant use and

- the solid waste and noise emissions’

minimization. [2]

It requires the environmental oriented monitoring

in the manufacturing company [16] and the optimization

of maintenance management [22]. By application of

wear-resistant complexes by modifying its surface

properties the improvement of working efficiency of

cutting tools can be determined [24]. Also important

activity in the innovative manufacturing processes the

evaluation of machine tool quality [11] and different

machining procedures such as rotational turning [19] and

hard turning [26], furthermore optimization of

manufacturing operations e.g. milling [12].

The engineering components are frequently

subjected to high levels of loads and temperature [5].

The technological quality of machined component can

be evaluated by the surface quality [4] and surface

integrity [10]. Finishing surface machining procedures

differ in their capabilities in their

- mechanical and thermal damage,

- residual stresses and

- materials [9].

According to the kinematics of burnishing it can

be classified into two groups:

- dynamic, and

- static [3].

According to the deformation element the

burnishing process can be classified:

- ball burnishing,

- roller burnishing

According to executing mechanisms finishing

surface machining procedures can be divided into two

types:

- which involves material loss such as grinding

[14], honing [17], rotational turning [19], hard

turning [26].

- which depends on plastic deformation of the

surface where there is no material loss [5].

According to the localization of the surface to be

burnished, it can be:

- outer cylindrical surface,

- inner cylindrical surface, and

- flat surface.

Burnishing is an example to the second one (Fig.1) [15].

The advantages of diamond burnishing are:

- the wear resistance and fatigue stress improves

[7].

- the mechanical features of the workpiece are

improved as well [13].

- the surface of the workpiece will be smooth

because its layer undergoes on an intensive

plastic deformation [1].

- cost effective method, it can easily be applied

[13].

Fig. 1. A schematic diagram of a surface micro-contour

deformation by a spherical burnishing tool [15]

The analysis of ball burnishing can effectively be

performed as an interesting application in the flexible

manufacturing system [8] by the adaption of

machinability investigation of metal matrix composites

[18].

Burnishing can be used for different workpiece

materials, such as aluminium, bronze, polymers, brass,

titanium, nickel, copper and different types of steels [3],

[21].

Tools used in these processes can be constructed into

- a fix system, orflexible, supplied with a

calibrated spring [25].



95

The quality of burnishing depends on a lot of input

parameters, among them can be found as follows:

- burnishing operational parameters [23]

o speed,

o feed,

o force,

o number of passes;

- material of the burnishing tools

o PCD,

o carbide,

o ceramic;

- shape of the burnishing tools

o spherical,

o semi-cylindrical;

- dimension of the tip,

- machine tool, and

- lubricanttype and viscosity. The task of

optimization requires a great number of experiments,

when even only a few parameters are taken into account.

By using Taguchy type experimental design [3], [20]

model the response function can be determined which is

valid in between the minimum and maximum values of

the input parameters.

In our experiments the input parameters were:

burnishing speed, (v),

feed, (f), and

burnishing force (F),

and the output parameters were:

surface roughness (SR)

the improvement ratio of surface roughness (I).

2 EXPERIMENTAL WORK

2.1 Experimental conditions The experimental setup of sliding burnishing is shown

on Fig. 2.

Fig. 2. Experimental setup of the sliding burnishing

Workpiece material is steel C45, its chemical

composition is shown in Table 1.

Before burnishing the surfaces of the specimen were

grinded. Geometrical dimension of specimen is shown in

the middle of Fig. 3.a and Fig. 3.b. Each specimen

contained 5 different experimental surfaces. Among

them 1-4 could be used for the examination of different

operational parameters and on the 5th one the features of

the ground surface remained. The outer dimensions of

the specimen were D = 49 mm and L = 190 mm.

OPTIMUM D420x1500 type universal lathe was

used as the machine tool for burnishing experiments.

The surface roughness of the workpiece was

measured by the TalySurf520 3D surface roughness

measuring equipment (Fig. 3.) after grinding (before

burnishing) and after burnishing. All the measurements

were executed on a surface having 2.0x2.0 mm

dimensions on five different positions on the periphery

of the workpiece, which average was calculated in all

cases. The improvement of the Root-Mean-Square

Deviation of the Surface (Sq) was determined after

definition of the improvement ratio of surface roughness

(ISq):

𝐼𝑆𝑞 =𝑆𝑞𝑏−𝑆𝑞𝑎

𝑆𝑞𝑏∙ 100, % (1)

where:

ISq is the improvement ratio of surface roughness Sq

Sqb is the surface roughness Sq before burnishing

Sqa is the surface roughness Sq after burnishing

Fig. 3. Measurement with the TalySurf520 3D surface

roughness measuring equipment

2.2 Experimental design In the applied Factorial Experiment Design the chosen

values of the input parameter intervals were:

- burnishing speed v=180 m/min ÷ 277 m/min;

- feed f=0.05 mm/rev ÷ 0.10 mm/rev; and

- burnishing force from 45 N up to 82 N (Table 1).

when the kinematic viscosity of the friction reducing oil

was: ν=70 mm2/s. In this examinations the number of

passes of burnishing was only one.

The adjusted values of input parameters are shown in

Table 1.

The parameters measured on the 3D measuring machine

can be recorded according to ISO 25178 standards as

well. The ISO 25178 standard deals with the surface

roughness parameters [27]. Five main parameter groups

are in the standard ISO 25178 (Fig. 4.).

Table 1, Matrix of experimental design



96

Number of

experiments Actual values

�̃�1, v �̃�2, f �̃�3, F

Burnishing

speed,

m/min

Feed,

mm/rev

Force

N

1 180 0.05 45

2 277 0.05 45

3 180 0.10 45

4 277 0.10 45

5 180 0.05 82

6 277 0.05 82

7 180 0.10 82

8 277 0.10 82

Fig. 4. Experimental setup of the sliding burnishing

The “Height parameters” contain the following 3D

parameters:

- Sq root mean square height of the surface;

- Ssk Skewness of height distribution;

- Sku Kurtosis of height distribution;

- Sp maximum height of peaks;

- Sv maximum height of valleys;

- Sz maximum height of the surface;

- Sa Arithmetical mean height of the

surface.

In this study we examined only the values of the Sq root

mean square height of the surface, and we made the

conclusion for this parameter. After calculation of

improvement ratio of surface roughness (ISq) on the

base of Equation 1 the function of the improvement ratio

of surface roughness (ISq) can be calculated in the form

of Equation 2.

𝐼𝑆𝑞 = 𝑘0 + 𝑘1𝑣 + 𝑘2𝑓 + 𝑘3𝐹 + 𝑘12𝑣 ∙ 𝑓+ 𝑘13𝑣 ∙ 𝑓 + 𝑘23𝑓 ∙ 𝐹+ 𝑘123𝑣 ∙ 𝑓 ∙ 𝐹

(2)

2.3 Results of measured data

The measured values of the experiments are in Table 2.

and Fig. 6. As the independent input parameters, it

contains the dimensionless coded parameters too.

Table 2, Results of the measurements

No of

exp. Coded values Sq, µm

𝑥1 𝑥2 𝑥3 Before After

Burnishing

1 -1 -1 -1

0.4575

0.3013

2 +1 -1 -1 0.3139

3 -1 +1 -1 0.2438

4 +1 +1 -1 0.2607

5 -1 -1 +1

0.4478

0.7215

6 +1 -1 +1 0.9738

7 -1 +1 +1 0.2856

8 +1 +1 +1 0.2482

In Table 2 the coded values relate to the investigated

actual parameters, where -1 means the lower value while

+1 the upper value of the parameter.

Measured average surface roughness values of the

ground workpieces (before burnishing) are:

- Sq=0.4575 µm, which is used for experiments

done by F=45 N burnishing force, while

- Sq=0.4478 µm, which is used for experiments

done by F=45 N burnishing force.

The left side of Table 2 demonstrates the 3D surface

topography pictures in case of 42 N burnishing force and

the right side demonstrates ones in case of 82 N. On the

basis of 2 mm x 2 mm surfaces. According to the

equation (1), the ISq improvement ratio of surface

roughness was calculated from the measured data. From

the ISa value the empiric formula (3) was determined

with the method of factorial experiment design.

Fig. 6. Demonstration of the improvement ratio of

surface roughness ISq



97

Sq5=0,4575 μm

Sq4=0,2607 μm

Sq3=0,2438 μm

Sq2=0,3139 μm

Sq1=0,3013 μm

a)

Sq5=0,4478 μm

Sq4=0,2482 μm

Sq3=0,2856 μm

Sq2=0,9738 μm

Sq1=0,7215 μm

b)

Fig.5. Surface topography after burnishing, a) burnishing force F=45 N, b) F=82 N

𝐼𝑆𝑞 = −23.197 + 1.464 · 𝑣 + 1.165 · 103 ∙ 𝑓 + 1.068 ∙ 𝐹 + 16.52 ∙ 𝑣 ∙ 𝑓 +0.033 ∙ 𝑣 ∙ 𝑓 + 19.517 ∙ 𝑓 ∙ 𝐹 + 0.363 ∙ 𝑣 ∙ 𝑓 ∙ 𝐹

(3)



98

After substitution into equation (3) we can get the

featuring points of the 3D diagram, which can be seen in

Fig. 6. It demonstrates that in our experiments surface

roughness of the workpiece is improving after

burnishing when the value of ISq is greater than zero that

is when its value is positive.

Figure 6 shows the top views and 3D surface

roughness profiles of burnished surfaces of the

workpiece after burnishing. Fig. 5a shows the results

when burnishing force is F=45 N, while Fig. 5b relates to

F=82 N.

3 CONCLUSIONS On the base of Fig. 5 it can be conclude that the

experimentally determined value of improvement ratio

of surface roughness depended particularly on the extent

of burnishing force and feed rate. The effect of increase

of feed in case of smaller burnishing speed (45 m/min) is

larger 12.57%) than by application of larger (82 m/min)

speed (11.62%) when smaller burnishing force (45N).

With the application of larger burnishing force (82N) the

improvement of surface roughness is 8.35% in case of

smaller feed (0.05 mm/rev). In the case of the larger feed

(0.1 mm/rev) the diminishing is 56.34%. Generally, in

the case of smaller burnishing force the improvement of

surface roughness is better than when larger force is

applied.

ACKNOWLEDGEMENTS

This research was partially carried out within the

framework of the Center of Excellence of Innovative

Engineering Design and Technologies at the University

of Miskolc. The research work was partially supported

by the OTKA project No.: K116843.

REFERENCES

[1] Brinksmeier, E.; Garbrecht, M.; Meyer, D. (2008)

Cold surface hardening. Manufacturing

Technology, CIRP Annals, vol. 57 1, p. 541-544.

[2] Coteţiu, R., Kuric, I., Novak-Marcincin, J.,

Ungureanu, N. (2005) New Trends in Mechanical

Design and Technologies. Ed. Risoprint, Cluj-

Napoca, 224 pag. ISBN 973- 751-084-4

[3] Deepak, Mahajan; Ravindra, Tajane (2013) A

review on ball burnishing process. International

Journal of Scientific and Research Publications,

vol. 3. Issue 4, April, ISSN 2250-3153

[4] Durakbasa, M. Numan; Akdogan, Anil, Vanli; Ali

Serdar; Bulutsuz, Asli Gunay (2015) Optimization

of end milling parameters and determination of the

effects of edge profile for high surface quality of

AISI H13 steel by using precise and fast

measurements. Measurement, vol. 68, ISSN 1311-

8080 (Printed Version), p. 92–99.

[5] El-Axir, M. H.; El-Khabeery, M. M. (2014) Ball

burnishing process optimization for aluminum

alloy using Taguchi technique. International

Journal of Mechanical Engineering (IJME),

ISSN(P) 2319-2240 ISSN(E) 2319-2259, vol. 3,

Issue 1, Jan. p. 1-14.

[6] Fridrik, L. (1987) Chosen chapters from the topics

of experimental design of production engineering,

Műszaki Könyvkiadó, Budapest, (In Hungarian)

[7] Hassan, A. M.; Momani, A. M .S. (2000), Further

improvements in some properties of shot peened

components using the burnishing process, Int. J.

Mach. Tools Manuf., vol. 40, Iss. 12, p. 1775–1786

[8] Košťál, Peter, Mudriková, Andrea (2012)

Laboratory of Flexible Manufacturing System.

Advanced Materials Research. ISSN 1022-6680(P).

- ISSN 1662-8985(E). - Vol. 429, p. 31-36.

[9] Kragelsky, I. V. (1981) Tribology Handbook, Mir,

Moscow.

[10] Krolczyk, G.; Nieslony, P. and Legutko, S. (2014)

Microhardness and Surface Integrity in Turning

Process of Duplex Stainless Steel (DSS) for Different

Cutting Conditions, Journal of Materials Engineering

and Performance, vol. 23, no. 3, p. 859–866.

[11] Kuric, Ivan (2011) Evaluation of machine tool

quality. International Journal for Quality

research, Vol.5, No.4, p. 269-275

[12] Lancea, C.; Ivan, N.V.; Chicoş, L.A.; Oancea, Gh.

(2008) Optimization of CNC Milling Files since

CAD Phases, Annals of DAAAM for 2008 &

Proceedings of the 19th International DAAAM

Symposium Intelligent Manufacturing &

Automation: Focus on Next Generation of

Intelligent Systems and Solutions, 22-25th October,

Trnava, Slovakia, ISSN 1726-9679, p. 741-742.

[13] Luo, H. Y.; Liu, J. Y.; Wang, L. J.; Zhong, Q. P.

(2006), Investigation of the burnishing force during

the burnishing process with a cylindrical surfaced

tool. Proceedings Inst Mech Eng Part B-J Eng

Manuf. vol. 220, p. 893–904.

[14] Novák, Martin. (2012). Surfaces with High

Precision of Roughness after Grinding.

Manufacturing Technology, vol. 12, p. 66-70.

[15] Rozenberg, O. A.; Shulzhenko, A. A.; Mamalis, A.

G.; Gargin, V. G.; Sokhan, S. V. (2003)

Manufacture of tips for diamond burnishing and

dressing probes for abrasive wheels with diamond

composition thermal material AKTM®. Journal of

Material Science, vol. 38, p. 789-794

[16] Rusko, Miroslav; Kralikova, Ruzena (2013)

Implementation of environmental oriented

monitoring in the manufacturing company.

Advanced Materials Research, vols. 816-817, p.

1225-1230

[17] Szabó, Ottó (2015) Stochastic modeling of honing

processes. Acta Tehnica Corviniensis – Bulletin of

Engineering, Tome VIII, Fascicule 2, April – June,

ISSN 2067 – 3809, p. 157-159

[18] Szalay, Tibor; Czampa, Miklós; Markos, Sándor;

Farkas, Balázs (2012) Investigation of

machinability of iron based metal matrix composite

(MMC) powder metallurgy parts. In: Muhammed

Hasan Aslan, Ahmet Yavuz Oral (editor) 2nd

International advances in applied physics and



99

materials science congress: AIP Conference

Proceedings, Volume 1476. Antalya, Turkye,

2012.04.26-2012.04.29. Melville: American

Institute of Physics, ISBN: 978-0-7354-1085-5, p.

300-303.

[19] Sztankovics, István; Kundrák, János (2014) Effect

of the Inclination Angle on the Defining Parameters

of Chip Removal in Rotational Turning,

Manufacturing Technology, ISSN 1213–2489, p.:

97-104.

[20] Taguchi, G. (1987) System of experiment design, 1.

Experimental design, UNIPUB, KRAUS

INTERNATIONAL PUBLICATIONS, White Plains,

New York, ISBN 0-527-91621-8

[21] Tanaka, H.; Yanagi, K. (2011) Geometrical and

material modification of stainless steel and

aluminum alloy surfaces induced by fine burnishing

process. 8039 Proceedings ASPE 2011 Spring

Topical Meeting Structured and Freeform Surfaces,

2011 Spring Topical Meeting, University of North

Carolina at Charlotte Campus, Charlotte, North

Carolina, March, p. 96-100.

[22] Ungureanu, Nicolae; Ungureanu, Miorita; Cotetiu,

Adriana; Barisic, Branimir; Grozav, Sorin (2010)

Principles of the maintenance management.

Scientific Bulletin, Serie C, Volume XXIV,

Fascicle: Mechanics, Tribology, Machine

Manufacturing Technology, ISSN 1224-3264, p.

69-72

[23] Varga, G.; Sovilj, B.; Pasztor, I. (2013)

Experimental analysis of sliding burnishing,

Academic Journal of manufacturing engineering,

ISSN: 1583-7904, vol. 11, Issue 3, p. 06-11.

[24] Vereschaka, A. Alexey: (2013) Improvement of

working efficiency of cutting tools by modifying its

surface properties by application of wear-resistant

complexes. Advanced Materials Research. Vols.

712-715. Trans Tech Publications, Switzerland,

June. p 347-351.

[25] Vukelic, D., Miljanic, D., Randjelovic, S., Budak,

I., Dzunic, D., Eric, M., Pan, M., (2013), A

burnishing process based on the optimal depth of

workpiece penetration, Materials and technology,

vol. 47, p. 43-51

[26] Zębala, W.; Siwiec, J. (2012) Hard Turning of Cold

Work Tool Steel with CBN Tools, Advances in

Manufacturing Science and Technology, 36/4 19-32

ISSN 1895-9881, p. 96-101

[27] ISO 25178 part 2 (2012) Geometrical product

specification (GPS) - surface texture: areal - part2:

Terms, definitions and surface texture parameters.

International Organization for Standardization

Authors’ addresses 1Dr. Gyula, Varga, associate professor, University of

Miskolc, Egyetemváros, 1., [email protected] 2Dr. Ferenc, Szigeti, professor, head of department,

College of Nyíregyháza, Sóstói u. 31/B, [email protected] 2Dr. Gergely, Dezső, professor, College of Nyíregyháza,

Sóstói u. 31/B, [email protected]

Contact person *Dr. Gyula, Varga, associate professor, University of

Miskolc, Egyetemváros, 1., [email protected]

mailto:[email protected]

buletin ŞtiinŢific, seria c, fascicola: mecanică ... · buletin ŞtiinŢific, seria c,...

Documents