Improving Surface Finish and Hardness For M.S. Cylinder Using Roller Burnishing
International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 3 Issue 1, April 2014
Improving Surface Finish and Hardness for M.S. Cylinder using Roller
Burnishing
Dinesh Kumar*, Alok Kumar**
*Department of Mechanical Engineering, IIT Patna, India
** Department of Mechanical Engineering, NIT Patna, India
Abstract
The high surface finish is required for proper working of
the machine parts with long life. To get high surface
finish lapping and honing processes are in use. These
processes are costlier and time consuming. So there is a
demand of time for a process which gives good surface
finish economically. This problem has been overcome
by using burnishing technique. In this technique (For
external surface) a roller is pressed against a rotating
cylindrical work piece. There is a plastic deformation of
the crests which go into deep valley. Experimental study
has been done by changing the interference between
roller and cylinder. Study of surface finish and hardness
has been done for different interferences. The other
surface property such as fatigue strength also increases
with this process. This process consume very less time
and less cost as compared to lapping and honing but
gives almost same surface finish as compared to honing
and lapping. This project will be profitable to the
industry that finishes the external cylindrical surface.
In this process pressure and friction is used to reduce the
height of peaks and valley.
1.1
Types of Burnishing
(i)
External burnishing
(ii)
Internal burnishing
(iii)
Burnishing of flat surfaces
(iv)
Thread burnishing
(i) External Burnishing: This is used for burnishing of
external cylindrical surfaces. In this type of burnishing
rollers are pressed against cylindrical surface. As shown
in Fig.1
Keywords - Roller burnishing; Telesurf; Surface
integrity; Hardness
I.
Introduction
The surface finish is an important parameter that is to be
controlled for desired value, so that machine work
properly and proper fit is to be obtained. Existing
methods that are used such as honing, lapping are time
consuming process and does not change properties of the
machined part. Burnishing is a surface finishing process
that is very fast ,improves the surface properties of
machined part and surface finish obtained is compatible
to that of conventional one. This process require
optimizations of various variables such as speed of tool,
interference between tool and work ,material of work
piece and tool material. Above all also fatigue strength
of material improves which is another advantage of
burnishing over other conventional processes. Quality of
work gets improved by this process.
Figure 1 : External Burnishing
(ii) Internal Burnishing: This type of burnishing as use
to burnishing the internal surface to this type of
burnishing a ball having interference with bore is
pressed through sleeve. As shown in Fig. 2
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Figure 2 : Internal Burnishing
47
International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 3 Issue 1, April 2014
(iii) Burnishing of flat surfaces: This is used for the
finishing the flat surface.
(iv)Thread Burnishing: This is used for thread
finishing. An attempt is made to study the phenomenon
of micro finishing. Ball bearings are used as burnishing
tool and universal testing machine is used to apply
pressure.
1.2 Literature Survey
Roller burnishing is a cold working surface treatment
process to generate a uniform and work hardened
surface. This study presents two internal roller
burnishing tools to perform roller burnishing process on
mild steel under different speeds. Burnishing speed
impact on surface roughness and surface hardness has
been examined.
Hassan [2] worked on the effects of ball- and rollerburnishing on the surface roughness and hardness of
some non-ferrous metals. The results show that
improvements in the surface roughness and increases in
the surface hardness were achieved by the application of
both ball burnishing and roller burnishing with the nonferrous metals under consideration.
Zhanga et al. [2] Worked on Influence of roller
burnishing (RB) on high cycle fatigue properties of the
hot-rolled Mg12Gd3Y (wt. %) magnesium alloy was
investigated. RB can significantly improve the fatigue
life of the Mg12Gd3Y alloy.
El-Khabeery et al. [3] worked on the investigation of the
effect of roller-burnishing upon surface roughness,
surface micro hardness and residual stress of 6061-T6
aluminum alloy. The residual stress distribution in the
surface region that was burnished is determined using a
deflection-etching technique.
Xia et al. [5] Worked on the smoothing mechanism of
burnishing was established, in which the geometries of
burnishing tool and workpiece, the microscopic
topography of the machined surface and the mechanical
properties of workpiece are taken into consideration. The
elasto-plastic deformation law of the cross-section of a
stripy asperity is established by the solutions to the
BoussinesqFlamant problem and then by the slip-line
field theory.
Klocke et al. [6] worked on the roller burnishing of hard
turned surface in which a hydrostatically borne ceramic
ball rolls over the component surface under high
pressures. The roughness peaks are flattened and the
quality of the workpiece surface is improved. When
combined with hard turning, this process provides a
manufacturing alternative to grinding and honing
operations.
II.
Design of Experimental Setup
Design has been done keeping in mind easy conduction
of experiment, self alignment of tool, higher accuracy in
sizes and surface finish and hardness of tool, tool feed,
test specimen quality and straightness has been kept in
mind during design of experimental setup.
Various design as well as description of machine tool is
given below.
2.1 Loading Machine
Lathe machine has been used to carry out the tests. Load
is applied by holding roller burnishing tool in tool post
of Lathe machine and specimen held in the chuck which
is rotating. Dial indicator is used to note the value of
interference applied. Different attachment is made for
dial indicator. Speed of tool with which it was moving is
kept constant.
Figure 3 : Loading on Lathe machine
2.2 Production of tool and Test Specimen
(i) Tool
SAE 60 material bearing has been as a part of roller
burnishing tool and hardness of the tool material is
64HRC.
Figure 4 : Roller Burnishing Tool
(ii) Dimension of Tool
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Diameter of Roller: 43 mm
Shank Thickness : 28 mm
48
International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 3 Issue 1, April 2014
2.3 Test Specimen
(i) Material: Mild Steel
Figure 6 : Lathe Machine
Lathe Machine Specifications
Figure 5 : Job1, Job2, Job3, Job4 and Job5
(ii) Dimensions
Specimen No
1
2
3
4
5
Make
: VEECO
Model
: 2002
Center Distance: 120 mm
Motor
: 1 HP
Bed Length
: 4 Feet
External Diameter (mm)
34
34
34.5
34
34
(ii) Hardness Testing Machine
Dimensions were written above. Proper care was taken
while turning the external surface of cylindrical work
pieces which are required for burnishing. The effect of
following parameters was considered:
1. External diameter
2. Surface finish of external surface
3. Surface hardness
4. Interference
This is used to calculate the external surface hardness of
test specimen before and after burnishing.
Rockwell hardness Tester Specifications
Ball diameter :
1/16
Minor load
:
10 Kg
Major load
:
100 Kg
Make
:
N.K. Enterprises
Type
:
6402
(iii) Inspection of Test Specimen
The surface finishes of specimens were checked by
using a Telesurf. Stylus was moved over a length of 10
mm and value of surface finish was indicated by
indicator.
The surface hardness of specimens were calculated by
using Rockwell hardness machine. The diamond
indenter is used to calculate the hardness of specimens.
The value of surface finish and hardness of other
specimens were calculated before and after burnishing.
2.4 Equipment Specifications
The manufacturing and testing equipments used for the
experiments were as follows
(i) Lathe Lathe was used for both turning and
burnishing processes on cylindrical work pieces.
Figure 7 : Rockwell Hardness Tester
(iii) Dial Gauge
It is used to calculate the interference that we are given
to roller burnishing tool.
Dial Gauge specifications
Make
:
Baker
Type
: JO 8A
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49
International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 3 Issue 1, April 2014
4. TELESURF
3.2 Roughness recorded after burnishing
This was used for checking surface finish as well to
draw surface irregularities profile A power drive
transverse and Stylus across the surface to be checked.
Stylus moves horizontally along the surface irregularities
and the detectors movement is converted into a
corresponding A.C. electrical signal.
Table 2 : Reading of surface roughness after burnishing
Sample
No
Interference
()
Roughness (m)
I
II
III
Av.
Value
(m)
1.
20
4.07
3.53
3.25
3.61
2.
3.
30
60
1.5
0.6
2.65
1.03
2.69
0.92
2.28
0.85
4.
80
0.6
0.52
0.93
0.69
5.
120
0.46
0.27
0.35
0.36
3.3 Hardness Recorded Before Burnishing = 66 B
Figure 8: Calculation of Surface roughness before and
after Roller Burnishing
3.4 Hardness Recorded After Burnishing
Table 3 : Hardness recorded after burnishing
SPECIFICATIONS:
Make: MITUTOYO SURFTEST ARPRET
Detector Principle: Moving magnet
Stylus: (i) Material Diamond
(ii) Shape Conical included angle 60
(iii) Radius 1 mm
Hardness (B)
1.
Interfe
rence
()
20
2.
3.
4.
First test has been conducted with interference 0.0 and
the roughness was checked then the another specimen
having interference 20.0 and similarly another end
following result were obtained before after burnishing
with straining rate 30.
5.
3.1 Roughness recorded before burnishing
The experiments conducted were aimed to study the
effect of burnishing operation to improve the surface
topography and surface accuracy.
The main objective was to find out the effect of varying
interference on surface finish obtained. Also to find out
how hardness and load required for movement of tool at
prespecific value, varies.
III.
Observation and Analysis
Table 1 :
burnishing
Sample
No
1.
2.
3.
4.
5.
Sample No
Reading of surface roughness before
Roughness (m)
I
5.63
5.80
6.02
5.36
6.05
II
5.23
5.85
5.85
5.63
5.38
III
5.65
5.40
5.43
6.02
5.53
Av.
Value(m)
5.5
5.68
5.76
5.67
5.65
IV.
II
III
82
82.9
83.5
Av.
Value
(m)
82.80
30
60
80
83
81.5
83
84.9
82
86
81
80.5
83.5
82.97
81.33
84.61
120
82
80
81
81.00
Results and Conclusions
4.1 Results
The results obtained was tabled and observed that
1. As interference increases finish obtained
increases. It becomes maximum at a particular
interference value and then decreases.
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50
International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 0882
Volume 3 Issue 1, April 2014
2. Load required passing the tool increases with
increase in interference.
3. Surface hardness also increases with interference
increases.
4.2 Conclusion
With increase in interference the asperities are affected
more and increase in finish is obtained. After a particular
value the surface finish starts decreasing. It is due to the
damage done by tool to the specimen during its
movement.
1. Maximum finish is obtained with interference
120 um.
2. Average improvement in surface finish with
interference 120 um was 93.4 %.
3. Maximum hardness is obtained with interference
80 um.
4. Average increase in hardness with interference
80um has been observed 22 %.
5. Average increase in hardness has been observed
as 18.5% with interference 120 um which has
result in optimum surface finish.
6. Slight damage of tool has been observed with
specimen number 4.
7. Axial force required with increase in
interference.
Journal of Machine Tools & Manufacture 41 (2001)
17051719.
[5] Feng Lei Li et al., Analytical prediction and
experimental verification of surface roughness during
the burnishing process, International Journal of Machine
Tools & Manufacture 62 (2012) 6775 .
[6] F. Klocke, J. Liermann, Roller Burnishing of Hard
Turned Surfaces Int. J. Mach. Tools Manufact. Vol. 38,
Nos 5-6, pp. 419-423, 1998.
REFERENCES
Books:
[1] D.R. Askeland, P.P. Fulay, D.K. Bhattacharya,
Material Science and Engineering, 2nd ed, Cengage,
2010, India
Journal Papers:
[2] A.M. Hassan, The effects of ball- and rollerburnishing on the surface roughness and hardness of
some non-ferrous metals, Journal of Materials
Processing Technology 72 (1997) 385391.
[3] P. Zhanga et al., Effect of roller burnishing on
fatigue properties of the hot-rolled Mg12Gd
3Ymagnesium alloy, Materials Chemistry and Physics
124 (2010) 835840
[4] M.M. El-Khabeery, M.H. El-Axir, Experimental
techniques for studying the effects of milling rollerburnishing parameters on surface integrity International
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