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Finishing Operations to Enhance Surface Integrity of Parts

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 November 2022) | Viewed by 22516

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Prof. Dr. Gilles Dessein

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Guest Editor

Laboratoire Génie de Production LGP, Université de Toulouse, INP-ENIT, 65000 Tarbes, France
Interests: manufacturing; materials science; burnishing; surface integrity

Prof. Dr. J. Antonio Travieso-Rodriguez

E-Mail Website
Guest Editor

Department of Mechanical Engineering, Universitat Politècnica de Catalunya, 08019 Barcelona, Spain
Interests: manufacturing; burnishing; surface integrity; additive manufacturing
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Dear Colleagues,

Surface integrity management is remarkably important when metal alloys are used to manufacture relevant parts. Advanced materials such as titanium, nickel alloys, non-ferrous alloys, or special steels make surface integrity preservation after machining particularly difficult. Consequently, thorough finishing techniques are required to rectify the surface integrity.

Engineering surfaces that exemplify the importance of surface integrity control are typically found in the transportation industry. Pieces formed by complex curved surfaces, such as turbine blades or landing gears, and molds and dies for upsetting operations, are good examples. These kinds of parts are often manufactured through 3 or 5 axis machining with the aid of successive adjacent passes of hemispherical tools, whereas this ball-end milling strategy allows one to achieve complex surfaces by following the desired shape through NC interpolations generated by a CAM (it also has deep constraints).

In this context, processes like burnishing, honing, plateau-honing, grinding, and shot peening can contribute to improving the described surfaces in terms of texture, residual stress, and hardness, as well as for being easily maneuverable from a procedural point of view. This Special Issue is proposed to collect the research results about these kinds of finishing processes, which are very important to the transportation industry.

It is our pleasure to invite you to submit a manuscript for this Special Issue. Full papers, communications, and reviews are all welcome.

Prof. Dr. Gilles Dessein
Dr. J. Antonio Travieso-Rodriguez
Guest Editors

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Keywords

Finishing
Burnishing
Honing
Grinding
Shot peening
Surface integrity
Roughness

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Published Papers (10 papers)

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Research

18 pages, 7287 KiB

Open AccessArticle

Analysis of Ultrasonic Vibration-Assisted Ball Burnishing Process on the Tribological Behavior of AISI 316L Cylindrical Specimens

by Eric Velázquez-Corral, Vincent Wagner, Ramón Jerez-Mesa, Jordi Lluma, J. Antonio Travieso-Rodriguez and Gilles Dessein

Materials 2023, 16(16), 5595; https://doi.org/10.3390/ma16165595 - 12 Aug 2023

Cited by 2 | Viewed by 1223

Abstract

In this study, we analyzed the effects of vibration assistance, combined with a ball burnishing process, in terms of topology, residual stresses, and tribological properties on 316L shafts. The burnishing variables consisted of the variation of the input force, the number of passes, and the activation of the vibration assistance, which is based on a 40 kHz frequency and 8 μm of vibration amplitude, derived in a screening design of three factors. The results show that the medium–high level of burnishing force, high level of the number of passes, and the activation of the vibration assistance are the best options in order to improve the average roughness, the microstructure, the increase in the compressive residual stresses, and the wear enhancement, besides all variables being significant in the p-value analysis through ANOVA. Statistically, the vibration-assisted ball burnishing improved the average roughness by 2.9%, enlarged the von Mises stress on the surface by 11.5% and enhanced the wear resistance of a 316L shaft and WC-Co ball contact up to 7.3%. Full article

(This article belongs to the Special Issue Finishing Operations to Enhance Surface Integrity of Parts)

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12 pages, 2902 KiB

Open AccessArticle

Influence of the Stainless-Steel Microstructure on Tribological Behavior and Surface Integrity after Ball Burnishing

by Alejandra Torres, Nuria Cuadrado, Jordi Llumà, Montserrat Vilaseca and J. Antonio Travieso-Rodriguez

Materials 2022, 15(24), 8829; https://doi.org/10.3390/ma15248829 - 10 Dec 2022

Cited by 5 | Viewed by 2052

Abstract

Burnishing is a plastic deformation process that reduces roughness while increasing hardness by introducing compressive residual stresses near the surface zone. These improvements will depend mainly on two fundamental variables: the applied load and the friction derived from the tool–surface interaction. Nevertheless, microstructural differences in the materials have not yet been considered within this interaction. This leads to a generalization of the process that can result in the failure of industrial components. Therefore, the aim of this work is to study the microstructural influence of the ball-burnishing process from a tribological perspective. Thus, martensitic and austenitic stainless steels were evaluated in terms of friction and surface integrity. The results show that parameterizing the process according to the tool–surface interaction is critical since improvements depend on friction as a function of the availability of plastic deformation of the crystallographic structures. Full article

(This article belongs to the Special Issue Finishing Operations to Enhance Surface Integrity of Parts)

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19 pages, 36407 KiB

Open AccessArticle

Influence of Slide Burnishing Parameters on the Surface Layer Properties of Stainless Steel and Mean Positron Lifetime

by Agnieszka Skoczylas, Kazimierz Zaleski, Jakub Matuszak, Krzysztof Ciecieląg, Radosław Zaleski and Marek Gorgol

Materials 2022, 15(22), 8131; https://doi.org/10.3390/ma15228131 - 16 Nov 2022

Cited by 19 | Viewed by 2005

Abstract

This paper presents the results of an experimental study on the impact of slide burnishing on surface roughness parameters (Sa, Sz, Sp, Sv, Ssk, and Sku), topography, surface layer microhardness, residual stress, and mean positron lifetime (τ_mea_n). In the study, specimens of X6CrNiTi18 stainless steel were subjected to slide burnishing. The experimental variables were feed and slide burnishing force. The slide burnishing process led to changes in the surface structure and residual stress distribution and increased the surface layer microhardness. After slide burnishing, the analyzed roughness parameters decreased compared with their pre-treatment (grinding) values. The slide burnishing of X6CrNiTi18 steel specimens increased their degree of strengthening e from 8.77% to 42.74%, while the hardened layer thickness g_h increased after the treatment from about 10 µm to 100 µm. The maximum compressive residual stress was about 450 MPa, and the maximum depth of compressive residual stresses was g_σ = 1.1 mm. The positron mean lifetime τ_mean slightly yet systematically increased with the increase in burnishing force F, while an increase in feed led to changes of a different nature. Full article

(This article belongs to the Special Issue Finishing Operations to Enhance Surface Integrity of Parts)

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13 pages, 8816 KiB

Open AccessArticle

Investigation of Surface Integrity Induced by Various Finishing Processes of AISI 52100 Bearing Rings

by Nabil Jouini, Philippe Revel and Guillaume Thoquenne

Materials 2022, 15(10), 3710; https://doi.org/10.3390/ma15103710 - 22 May 2022

Cited by 7 | Viewed by 2164

Abstract

Surface integrity induced by finishing processes significantly affects the functional performance of machined components. In this work, three kinds of finishing processes, i.e., precision hard turning, conventional grinding, and sequential grinding and honing, were used for the finish machining of AISI 52100 bearing steel rings. The surface integrity induced by these finishing processes was studied via SEM investigations and residual stress measurements. To investigate rolling contact fatigue performance, contact fatigue tests were performed on a twin-disc testing machine. As the main results, the SEM observations show that precision hard turning and grinding introduce microstructural alterations. Indeed, in precision hard turning, a fine white layer (<1 μm) is observed on the top surface, followed by a thermally affected zone in the subsurface, and in grinding only, a white layer with 5 μm thickness is observed. However, no microstructural changes are found after sequential grinding and honing processes. White layers induced by precision hard turning and grinding possess compressive residual stresses. Grinding and sequential grinding and honing processes generate similar residual stress distributions, which are maximum and compressive at the machined surface and tensile at the subsurface depth of 15 μm. Precision hard turning generates a “hook”-shaped residual stress profile with maximum compressive value at the subsurface depth and thus contributes as a prenominal factor to the obtainment of the longest fatigue life with respect to other finishing processes. Due to the high quality of surface roughness (Ra = 0.05 μm), honing post grinding improves the fatigue life of bearing rings by 2.6 times in comparison with grinding. Subsurface compressive residual stresses, as well as low surface roughness, are key parameters for extending bearing fatigue life. Full article

(This article belongs to the Special Issue Finishing Operations to Enhance Surface Integrity of Parts)

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18 pages, 6427 KiB

Open AccessArticle

Influence of Axial Depth of Cut and Tool Position on Surface Quality and Chatter Appearance in Locally Supported Thin Floor Milling

by Mikel Casuso, Antonio Rubio-Mateos, Fernando Veiga and Aitzol Lamikiz

Materials 2022, 15(3), 731; https://doi.org/10.3390/ma15030731 - 19 Jan 2022

Cited by 8 | Viewed by 1779

Abstract

Thin floor machining is a challenging and demanding issue, due to vibrations that create poor surface quality. Several technologies have been developed to overcome this problem. Ad hoc fixtures for a given part geometry lead to meeting quality tolerances, but since they lack flexibility, they are expensive and not suitable for low manufacturing batches. On the contrary, flexible fixtures consisting of vacuum cups adaptable to a diversity of part geometries may not totally avoid vibrations, which greatly limits its use. The present study analyses the feasibility of thin floor milling in terms of vibration and roughness, in the cases where milling is conducted without back support, a usual situation when flexible fixtures are employed, so as to define the conditions for a stable milling in them and thus avoid the use of ad hoc fixtures. For that purpose, the change of modal parameters due to material removal and its influence on chatter appearance have been studied, by means of stability lobe diagrams and Fourier Transform analysis. Additionally, the relationship between surface roughness and chatter frequency, tooth passing frequency, and spindle frequency have been studied. Ploughing effect has also been observed during milling, and the factors that lead to the appearance of this undesirable effect have been analyzed, in order to avoid it. It has been proven that finish milling of thin floors without support in the axial direction of the mill can meet aeronautic tolerances and requirements, providing that proper cutting conditions and machining zones are selected. Full article

(This article belongs to the Special Issue Finishing Operations to Enhance Surface Integrity of Parts)

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21 pages, 3938 KiB

Open AccessArticle

Optimization and Sensitivity Analysis of the Cutting Conditions in Rough, Semi-Finish and Finish Honing

by Irene Buj-Corral, Lourdes Rodero-de-Lamo and Lluís Marco-Almagro

Materials 2022, 15(1), 75; https://doi.org/10.3390/ma15010075 - 23 Dec 2021

Cited by 7 | Viewed by 2445

Abstract

Honing processes are currently employed to obtain a cross-hatched pattern on the internal surfaces of cylinders that favors oil flow in combustion engines or hydraulic cylinders. The main aim of the present paper is to optimize the machining conditions in honing processes with respect to surface roughness, material removal rate and tool wear by means of the desirability function. Five process variables are considered: grain size, density, pressure, linear speed and tangential speed. Later, a sensitivity analysis is performed to determine the effect of the variation of the importance given to each response on the results of the optimization process. In the rough and semi-finish honing steps, variations of less than 5% of the importance value do not cause substantial changes in the optimization process. On the contrary, in the finish honing step, small changes in the importance values lead to modifications in the optimization process, mainly regarding pressure. Thus, the finish honing phase is more sensitive to changes in the optimization process than the rough and the semi-finish honing phases. The present paper will help users of honing machines to select proper values for the process variables. Full article

(This article belongs to the Special Issue Finishing Operations to Enhance Surface Integrity of Parts)

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14 pages, 4992 KiB

Open AccessArticle

A Comparative Analysis of Chemical, Thermal, and Mechanical Post-Process of Fused Filament Fabricated Polyetherimide Parts for Surface Quality Enhancement

by Ariadna Chueca de Bruijn, Giovanni Gómez-Gras and Marco A. Pérez

Materials 2021, 14(19), 5880; https://doi.org/10.3390/ma14195880 - 8 Oct 2021

Cited by 15 | Viewed by 2463

Abstract

Additive manufacturing technologies are increasingly being used in production systems because they shorten product development time and production cost, but surface integrity remains a limitation to meet the standards set by conventional manufacturing. In this research article, two chemical, one thermal, and three mechanical finishing operations are proposed to post-process fused filament fabricated Ultem 9085 parts. Their effects on the parts’ surface quality and dimensional accuracy (changes in their width, height, length, and mass) are examined through optical and electron scanning microscopy, and the advantages and disadvantages of each method are discussed. Microscope evaluation has proven to be a powerful tool to observe apparent differences and understand the nature of different morphological changes. Results indicate that chemical and thermal treatments and ball burnishing are good candidates to significantly enhance the finish of the parts, despite requiring the use of solvents or provoking dimensional changes to the parts. The effects of abrasive mechanical treatments are more moderate at a macroscopic scale, but the surface of the filaments suffers the most remarkable changes. Full article

(This article belongs to the Special Issue Finishing Operations to Enhance Surface Integrity of Parts)

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17 pages, 7842 KiB

Open AccessArticle

Ultrasonic Vibration-Assisted Ball Burnishing Tool for a Lathe Characterized by Acoustic Emission and Vibratory Measurements

by Ismael Fernández-Osete, Aida Estevez-Urra, Eric Velázquez-Corral, David Valentin, Jordi Llumà, Ramón Jerez-Mesa and J. Antonio Travieso-Rodriguez

Materials 2021, 14(19), 5746; https://doi.org/10.3390/ma14195746 - 1 Oct 2021

Cited by 5 | Viewed by 2433

Abstract

This paper focuses on a resonant system used to induce a low-amplitude movement and ultrasonic frequency to complement a ball burnishing process on a lathe. The system was characterized through the combination of different techniques. A full vibratory characterization of this process was undertaken with the purpose of demonstrating that the mechanical system—composed of the tool and the machine—does not present resonance phenomena during the execution of the operation that could lead to eventual failure. This dynamic analysis validates the adequateness of the tool when attached to an NC lathe, which is important to guarantee its future implementation in actual manufacturing contexts. A further aim was to confirm that the system succeeds in transmitting an oscillating signal throughout the material lattice. To this end, different static and dynamic techniques that measure different vibration ranges—including impact tests, acoustic emission measurement, and vibration measurement—were combined. An operational deflection shape model was also constructed. Results demonstrate that the only high frequency appearing in the process originated in the tool. The process was not affected by the presence of vibration assistance, nor by the burnishing preload or feed levels. Furthermore, the frequency of the assisting ultrasonic vibration was characterized and no signal due to possible damage in the material of the specimens was detected. These results demonstrate the suitability of the new tool in the vibration-assisted ball burnishing process. Full article

(This article belongs to the Special Issue Finishing Operations to Enhance Surface Integrity of Parts)

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13 pages, 2276 KiB

Open AccessArticle

Testing the Sandblasting Process in the Manufacturing of Reference Spheres for Non-Contact Metrology Applications

by Víctor Meana, Eduardo Cuesta and Braulio J. Álvarez

Materials 2021, 14(18), 5187; https://doi.org/10.3390/ma14185187 - 9 Sep 2021

Cited by 7 | Viewed by 2384

Abstract

To ensure that measurements can be made with non-contact metrology technologies, it is necessary to use verification and calibration procedures using precision artefacts as reference elements. In this environment, the need for increasingly accurate but also more cost-effective calibration artefacts is a clear demand in industry. The aim of this work is to demonstrate the feasibility of using low-cost precision spheres as reference artefacts in calibration and verification procedures of non-contact metrological equipment. Specifically, low-cost precision stainless steel spheres are used as reference artefacts. Obviously, for such spheres to be used as standard artefacts, it is necessary to change their optical behavior by removing their high brightness. For this purpose, the spheres are subjected to a manual sandblasting process, which is also a very low-cost process. The equipment used to validate the experiment is a laser triangulation sensor mounted on a Coordinate Measuring Machine (CMM). The CMM touch probe, which is much more accurate, will be used as a device for measuring the influence of sandblasting on the spheres. Subsequently, the influence of this post-processing is also checked with the laser triangulation sensor. Ultimately, the improvement in the quality of the point clouds captured by the laser sensor will be tested after removing the brightness, which distorts and reduces the quantity of points as well as the quality of the point clouds. In addition to the number of points obtained, the parameters used to study the effect of sandblasting on each sphere, both in contact probing and laser scanning, are the measured diameter, the form error, as well as the standard deviation of the point cloud regarding the best-fit sphere. Full article

(This article belongs to the Special Issue Finishing Operations to Enhance Surface Integrity of Parts)

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22 pages, 8894 KiB

Open AccessArticle

Impact of Ball Burnished Regular Reliefs on Fatigue Life of AISI 304 and 316L Austenitic Stainless Steels

by Stoyan Slavov, Diyan Dimitrov, Mariya Konsulova-Bakalova and Dimka Vasileva

Materials 2021, 14(10), 2529; https://doi.org/10.3390/ma14102529 - 13 May 2021

Cited by 12 | Viewed by 2328

Abstract

The present work describes an experimental investigation of the fatigue durability of AISI 304 and AISI 316L austenitic stainless steels, which have regular reliefs (RR) of the IV-th type, formed by ball burnishing (BB) on flat surfaces, using a computer numerical control (CNC) milling center. The methodology and the equipment used for obtaining regular reliefs, along with a vibration-induced fatigue test setup, are presented and described. The results from the BB process and the fatigue life experiments of the tested austenitic stainless steels are gathered, using the approach of factorial design experiments. It was found that the presence of RR of the IV-th type do not worsen the fatigue strength of the studied steels. The Pareto, t-test and Bayesian rule techniques are used to determine the main effects and the interactions of significance between ball burnishing regime parameters. A stochastic model is derived and is used to find when the probability of obtaining the maximum fatigue life of parts made of AISI 304 or 316L reaches its maximum value. It was found that when the deforming force, the amplitude of the sinewaves and their wavenumber are set at high values, and the feed rate is set at its low value, the probability to reach maximum fatigue life for the parts made of AISI 304 or 316L is equal to 97%. Full article

(This article belongs to the Special Issue Finishing Operations to Enhance Surface Integrity of Parts)

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