Diamond burnishing process parameters impact on the surface layer quality of the parts while aviation technology products manufacturing

Machine-building Engineering and Machine Science


Аuthors

Shvetsov A. N.*, Skuratov D. L.**

Samara National Research University named after Academician S.P. Korolev, 34, Moskovskoye shosse, Samara, 443086, Russia

*e-mail: shvecovalexey@yandex.ru
**e-mail: skuratov-sdl56@yandex.ru

Abstract

The effect of burnishing force, radius of diamond point sphere, initial roughness, tool advance and machining speed on the samples surface roughness, micro-hardness of surface layer, as well as circular and axial residual stresses was studied based on single-factor and full-factor experiments while performing diamond burnishing of the samples from the 15Cr12Ni2MoVWNNb-S (EP517-S) heat resistant wrought steel and 30CrMnSiNi2A high-resistance steel. Empirical power dependences were obtained linking the above said parameters of the diamond burnishing process with those defining the surface layer quality, namely with the surface roughness, maximum micro-hardness and strain hardening, maximum value of the circular residual compressive stresses and their maximum depth of occurrence, as well as maximum value of the axial compressive stresses.

The studies revealed that the main effect on the surface roughness at the burnishing force from 50 to 200 N was exerted by the tool sphere radius and tool advance, while at the force from 200 to 350 N these were the burnishing force and the tip sphere radius. In the case of the samples burnishing with natural diamond, the determining effect at the burnishing force from 50 to 350 N is the burnishing force and initial surface roughness. When machining the 30XGSN2A steel by the ASB-1 synthetic diamond, the same parameters as for the EP517-S steel burnishing have the greatest impact on the surface roughness. Radius of the diamond burnisher (ASB-1) and machining speed have the greatest impact on the micro-hardness value of the surface layer of the samples from both EP517-S and 30XGSN2A steel. At the same time, the burnishing force and diamond tip sphere radius have decisive impact while machining the samples from the EP517-S steel, and burnishing force and tool advance are the main factors while the samples from the 30XGSN2A steel machining. The tool sphere radius and advance have the greatest effect on the circular residual stresses forming by the tool with the ASB-1 diamond while the samples from the EP517-S steel burnishing, while both the tool sphere radius and burnishing force prevail while the 30XGSN2A steel burnishing. The most notable parameters affecting axial residual stresses while processing samples from the EP517-S steel are the sphere radius and the burnisher tracking force, and at the samples from the 30XGSN2A steel machining these are the tip sphere radius and the burnisher advance.

Samples made of 30CrMnSiNi2A steel processing by the ASB-1synthetic diamond had the same dependences temper as for the samples made of EP517-SH steel.

At the same time, during the processing of samples made of EP517-S steel the definite influence on strain hardening depth had burnishing force and radius of diamond point, but for samples made of 30CrMnSiNi2A steel – burnishing force and tool feed.

Generation of hoop locked-up stresses during the burnishing of samples made of EP517-S steel by tool with diamond ASB-1 was affected by the radius of diamond point and feed, on the other hand during the burnishing of samples made of 30CrMnSiNi2A steel there was another combination of significant factors: burnishing force and radius of diamond point.

Keywords:

burnishing with a diamond tool with a spherical working part, burnishing process elements, surface roughness, surface layer microhardness, compressive residual stresses

References

  1. Komkov V.A., Kokoreva O.G., Kursakov A.V. Investigation of possibilities to harden thin-wall elements of flying vehicles by surface plastic deformation. Aerospace MAI Journal, 2015, vol. 22, no. 2, pp. 132-136.

  2. Sulima A.M., Shulov V.A., Yagodkin Yu.D. Poverkhnostnyi sloi i ekspluatatsionnye svoistva detalei mashin (Surface layer and operational properties of machine parts), Moscow, Mashinostroenie, 1988, 240 p.

  3. Odintsov L.G. Uprochnenie i otdelka detalei poverkhnostnym plasticheskim deformirovaniem. Spravochnik (Hardening and finishing of parts by surface plastic deformation: a Handbook), Moscow, Mashinostroenie, 1987, 328 p.

  4. Odintsov L.G. Finishnaya obrabotka detalei almaznym vyglazhivaniem i vibrovyglazhivaniem (Finishing of parts with diamond burnishing and vibration smoothing), Moscow, Mashinostroenie, 1981, 160 p.

  5. Shvetsov A.N., Skuratov D.L. Vestnik mashinostroeniya, 2020, no. 5, pp. 82-86. DOI: 10.36652/0042-4633-2020-5-82-86

  6. Shvetcov A.N., Skuratov D.L. Investigation of Conditions of Processing Influence on Micro-Hardness Distribution in Surface Layer during Diamond Burnishing of Samples of FeC0.15Cr12Ni2 Steel. Key Engineering Materials, 2017, vol. 746, рр. 290-295. DOI: 10.4028/www.scientific.net/KEM.746.290

  7. Shvetcov A.N., Skuratov D.L. Evolution of the Residual Stresses Formation from FeC0.15Cr12Ni2 Steel in the Part Surface During the Diamond Smoothing. Procedia Engineering, 2017, vol. 176, no. 25, рр. 355–362. DOI: 10.1016/j.proeng.2017.02.332

  8. Torbilo V.M. Almaznoe vyglazhivanie (Diamond smoothing), Moscow, Mashinostroenie, 1972, 105 p.

  9. Totai A.V. Vestnik Bryanskogo gosudarstvennogo tekhnicheskogo universiteta, 2021, no. 12(109), pp. 37-47. DOI: 1030987/1999-8775-2021-12-37-47

  10. Zaharov E.N., Usachev D.V. An approach to the assessment of military-oriented aircraft engineering based on neural-like networks. Aerospace MAI Journal, 2021, vol. 28, no. 4, pp. 267-280. DOI: 10.34759/vst-2021-4-267-280

  11. Dal’skii A.M., Suslov A.G., Kosilova A.G., Meshcheryakov R.K. (eds). Spravochnik konstruktora-mashinostroitelya. V 2 t. (Handbook of the designer-machine builder. In 2 vols), 5th ed. Moscow, Mashinostroenie, 2001. Vol. 2, 944 p.

  12. Zaghal J., Molnár V., Benke M. Improving surface integrity by optimizing slide diamond burnishing parameters after hard turning of 42CrMo4 steel. International Journal of Advanced Manufacturing Technology, 2023, vol. 128, no. 5-6, pp. 1-17. DOI: 10.1007/s00170-023-12008-6

  13. Alekseev P.G. Tekhnologiya uprochneniya detalei mashin poverkhnostnoi plasticheskoi deformatsiei (Technology of hardening of machine parts by surface plastic deformation), Tula, Tul’skii politekhnicheskii institut, 1978, 80 p.

  14. Dzyura V., Maruschak P., Slavov S. et al. Evaluating Some Functional Properties of Surfaces with Partially Regular Microreliefs Formed by Ball-Burnishing. Machines, 2023, vol. 11, no. 6: 633. DOI: 10.3390/machines11060633

  15. Kluz R., Bucior M., Dzierwa A. et al. Effect of Diamond Burnishing on the Properties of FSW Joints of EN AW-2024 Aluminium Alloys. Applied Sciences, 2023, vol. 13, no. 3: 1305. DOI: 10.3390/app13031305

  16. Dezső G., Szigeti F., Varga G. Surface Hardness Modification of Selective Laser Melted Ti6Al4V Parts by Sliding Friction Diamond Burnishing. Periodica Polytechnica Mechanical Engineering, 2022, vol. 67, no. 1, pp. 59–69. DOI: 10.3311/PPme.21124

  17. Aydın M., Türköz M., Çakan A., Kalyoncu M. Optimization of Roller Burnishing Process Using Bees and Genetic Algorithm. 3rd International Conference on Applied Engineering and Natural Sciences (ICAENS – 2022; Konya, Turkey), pp. 650-654.

  18. Attabi S., Himour A., Laouar L., Motallebzadeh A. Mechanical and wear behaviors of 316L stainless steel after ball burnishing treatment. Journal of Materials Research and Technology, 2021, vol. 15, no. 7, pp. 3255-3267. DOI: 10.1016/j.jmrt.2021.09.081

  19. Ulhe P.N., Patil U.D., Patil C.R. Optimization of Roller Burnishing Process Parameters on Surface Roughness Using Response Surface Methodology, 9th International Conference of Materials Processing and Characterization (ICMPC-2019), 2019, vol. 18. Part 7, pp. 3632–3637. DOI: 10.1016/j.matpr.2019.07.295

  20. Bourebia M., Bouri A., Hamadache H. et al. Study of the effect burnishing on superficial hardness and hardening of S355JR steel using experimental planning. Energy Procedia, 2019, vol. 157, pp. 568-577. DOI: 10.1016/j.egypro.2018.11.221

  21. Shvetsov A.N. Povyshenie effektivnosti protsessa almaznogo vyglazhivaniya detalei GTD i aviaagregatov na osnove opredeleniya ratsional’nykh uslovii obrabotki (Improving the efficiency of the diamond smoothing process of GTD parts and aircraft units based on the determination of rational processing conditions). Ph.D. thesis. Samara, Samarskii universitet, 2021, 229 p.

  22. Technodinamika. Sistema shassi. Shassi dlya novogo IL-76MD-90A. URL: http://technodinamika.ru/competencies/systems/shassi

  23. Reznikov A.N. (ed.) Abrazivnaya i almaznaya obrabotka materialov: Spravochnik (Abrasive and diamond processing of materials. Handbook). Moscow, Mashinostroenie, 1977, 391 p.

mai.ru — informational site of MAI

Copyright © 1994-2024 by MAI