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OPTIMIZATION of BURNISHING PROCESS PARAMETERS on DIFFERENTLY HARDENED 20Mncr5 STEEL

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OPTIMIZATION of BURNISHING PROCESS PARAMETERS on DIFFERENTLY HARDENED 20Mncr5 STEEL OPTIMIZATION OF BURNISHING PROCESS PARAMETERS ON DIFFERENTLY HARDENED 20MnCr5 STEEL 1HIMANSHU KHANNA, 2HARISH PUNGOTRA, 3SANDEEP GANDOTRA 1M.TECH. STUDENT, BEANT COLLEGE OF ENGINEERING AND TECHNOLOGY GURDASPUR, PUNJAB 2ASSOCIATE PROFESSOR, DEPARTMENT OF MECHANICAL ENGINEERING, BEANT COLLEGE OF ENGINEERING & TECHNOLOGY, GURDASPUR - 143521, PUNJAB, INDIA 3ASSISTANT PROFESSOR, DEPARTMENT OF MECHANICAL ENGINEERING, BEANT COLLEGE OF ENGINEERING & TECHNOLOGY, GURDASPUR - 143521, PUNJAB, INDIA E-mail: [email protected], [email protected], [email protected] Abstract: Surface finish designates the geometry and microstructural superiority of the machined surface. Different operations such as grinding, lapping, honing, buffing, barrel rolling, polishing, super finishing, and burnishing are required to be performed to achieve the high surface finish. Amongst all, burnishing is a process where the hard roller or a ball tool is engaged to the workpiece to get the better surface finish. In the present study, using Taguchi approach preliminary plan is made for the experimentation then according to it a roller burnishing of the 20MnCr5 workpiece at different input conditions is performed. From the analysis, it is concluded that the hardness of the material is the main contributing factor for burnishing process. Keywords - Burnishing, Depth of penetration, Feed, Speed, Hardness, Surface roughness. I. INTRODUCTION Morimoto & Tamamura (1991) compared different types of ball burnishing tools and concluded that the For reliable performance and prolonged life of cemented carbide and silicon nitride ceramic ball-tool contemporary machinery, its components require not tool showed best results regarding surface roughness. only high geometrical and dimensional geometrical Hassan et al. (1996) compared machined and accuracy but also with low surface roughness. The burnished specimens of commercially pure surface roughness has a vital role in functional aluminium and brass material. Surface roughness, features like wear resistance, fatigue strength, hardness, ultimate tensile strength and fatigue corrosion resistance and power loss due to friction. strength before and after burnishing process were Inappropriately, normal machining methods like examined and results showed improvement after turning, milling or even classical grinding cannot burnishing process. Adel Mahmood Hassan (1997) meet this severe condition. Burnishing is a plastic used the simple ball and roller burnishing tools and deformation process used to finish surfaces. studied the effects of the burnishing force; number Burnishing is a cold-working process in which plastic passes on the surface roughness and surface hardness deformation takes place by applying pressure with a on aluminum and brass. Improvements in the surface hard and smooth ball or roller on a metallic surface. roughness and surface hardness were achieved by the Improvements in surface finish, surface hardness, application of both ball and roller burnisher. Hassan wear resistance, fatigue resistance, yield, tensile et al. (1998) examined the surface finish for ball- strength and corrosion resistance can be achieved by burnished brass components using the response the application of this process. As in this process, surface method and established a mathematical model there is no removal of the material from the surface of to burnishing force and the number of tool passes, the workpiece, so burnishing is a chipless finishing with the surface finish. Klocke & Liermann (1998) process. Roller burnishers are mostly used for concluded that the roughness peaks are flattened, and cylindrical surfaces, flat surfaces or to burnish large the quality of the workpiece improved using internal diameters. In roller burnishing a hard roller is hydrostatically borne ceramic ball rolls over the employed to improve surface specifications such as component surface under high pressures. Authors hardness, surface finish and wear resistance of the recommended that the combined hard turning and mechanical components. In Ball burnishing process burnishing provide a manufacturing alternative to hard metallic ball penetrates up to the prescribed grinding and honing operations. Ne´mat & Lyons depth to the pre-machined surface. The workpiece (2000) investigated on ball burnished mild steel and and burnishing tool move in a certain specified aluminum using a purpose-built burnishing tool and. direction, i.e., in the opposite direction or one is The assessed the effects of burnishing feed, force, moving, and other remains stationary. The surface speed and the number of passes on the surface roughness obtained after burnishing depends on the roughness and surface hardness. The experimental depth of penetration, speed, and lubricant used if any. results showed the improvements of 70% in surface Proceedings of IRF International Conference, 25th February, 2018, Kanyakumari, India 10 Optimization of Burnishing Process Parameters on Differently Hardened 20MnCr5 Steel quality after varying the mix of parameters. M.H. El- machining processes on a brass material on the basis Axir (2000) studied the influence of burnishing of microstructure, circularity and surface roughness. speed, force, feed, and number of passes on both The results showed that burnishing should be surface microhardness and roughness. The preferred to provide the optimum characteristics in relationship between residual stress, burnishing speed hole surfaces subjected to continuous deformation and force was presented for predicting the surface and corrosion. Babu et al., (2012) studied the microhardness and roughness under lubricated influence of various burnishing parameters on the conditions Chen & Shiou (2003) determined the surface characteristics i.e. microhardness and optimal plane ball-burnishing parameters for plastic microstructure, are evaluated, and discussed in the injection molding steel with four burnishing case of EN Series steels (EN 8, EN 24 and EN 31), parameters namely ball burnisher material, speed Alpha-beta brass and Aluminum alloy (AA6061). force and feed using Taguchi’s design of The burnishing parameters considered for studies experiments. Zhang & Lindemann (2005) worked on principally are burnishing speed, burnishing force, roller burnishing and improved the high cycle fatigue burnishing feed and number of passes. Taguchi performance. Authors suggested that roller technique was employed by them to identify the most burnishing is more effective than shot peening in influencing parameters on surface roughness. The enhancing the fatigue life. Hamadache (2006) effort was also made to determine the optimal developed a device for mechanical plastic burnishing parameters and the factors for the deformation of structural Rb40 steel using ball and scientific basis of such optimization. Patel and Patel, roller burnishing. The output parameters were (2013) presented a review of parametric optimization roughness, hardness, and wear resistance and authors of process parameters for roller burnishing process. recommended two number of passes for surface Roller burnishing tool is used to perform burnishing roughness and three passes for hard materials. process using different input and output parameters. Swirad, (2007) experimentally demonstrated the There are many parameters which can be optimized effect of burnishing parameters on steel fatigue for improved performance of surface hardness and strengths with his primary focus on possibilities of surface roughness. It has been used to impart certain sliding burnishing with cylindrical elements made of properties, such as corrosion, friction, wear and diamond composite with ceramic bonding phase. The fatigue resistance. Esme et al., (2013) worked on author identified that a new technology of sliding predictive modeling of ball burnishing process using burnishing with cylindrical elements of the diamond regression analysis and neural network by focusing composite could be used in effortless and easy way on two techniques, namely neural network techniques for smooth machining of various types of material. and regression, for predicting surface roughness in The cylindrical elements are easier to manufacture ball burnishing process. Values of surface roughness and simpler to grind, which reduces the costs of their predicted by the techniques were compared with production, when the contact zone “tool machined experimental values. Also, the effects of the main object” will wear, it can easily grinded in this way it burnishing parameters on surface roughness were was possible to extend its life several dozen times. determined. The surface roughness (Ra) was taken as Babu et al., (2008) worked on effects of internal the response variable, and burnishing force, roller burnishing on surface roughness and surface burnishing speed, the number of passes and feed rate hardness of mild steel.The authors observed that in were taken as input parameters. The relation between internal burnishing process, surface finish and surface the surface roughness and burnishing parameters was roughness of mild steel material increased with found out for measurement of the surface roughness. increase in burnishing speed due to repeated Akkurt et al. (2014) investigated surface finishing of deformation of surface irregularities with increased drilling, turning, reaming, grinding and roller burnishing speed. The surface finish and surface burnishing etc. Different hole surface finishing hardness increase with burnishing speed up to an processes
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