Effect of tangential misalignment in ultrasonic burnishing

Juha Huuki; Sampsa V. A. Laakso; Rizwan Ullah

doi:10.1016/j.promfg.2020.01.132

Effect of tangential misalignment in ultrasonic burnishing

Juha Huuki, Sampsa V. A. Laakso, Rizwan Ullah

Department of Energy and Mechanical Engineering

Research output: Chapter in Book/Report/Conference proceeding › Conference article in proceedings › Scientific › peer-review

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Abstract

Ultrasonic burnishing is a surface finishing process that produces fine surface roughness, improved geometrical accuracy, high compressive residual stresses and increased hardness. The method is suitable for finishing dies or other double curvature surfaces and it does not require changing of the fixturing setup after a machining process. The method has not however become commonly used in industry, because the technology has not been extensively tested. Technological parameters in ultrasonic burnishing includes the surface speed, distance between consecutive passes (or in machining terms, feed) and contact force. Ultrasonic burnishing is based on forging at an ultrasonic frequency of over 20,000 impacts per second and there is no material removal associated with the process. The technological parameters have been tested and recommended values have been recorded for some common work materials. One important parameter is the tangential alignment of the burnishing tool in regard to the workpiece surface normal. This parameter is easy to control in turning operations or with planar surfaces, but with a double curved surface the control of the angle is more difficult. All the previous research has been done on cylindrical or planar workpiece and therefore the tangential misalignment or the sensitivity of the surface integrity regarding the tangential misalignment has not been studied. This paper investigates the effect of the tangential misalignment of the burnishing tool and the effect on surface integrity. The results show that ultrasonic burnishing is suitable method for finishing workpiece surfaces even with inclined tool angle. The ultrasonic burnishing produced a beneficial surface integrity state on the workpiece surface with hardened material and improved surface quality. The surface micro-hardness increased by 1.4-6.7 %. At the same time, the average surface roughness (Ra) values decreased by 50-85 % depending on the misalignment angle.

Previous article in issue

Original language	English
Title of host publication	29th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM2019), June 24-28, 2019, Limerick, Ireland
Publisher	Elsevier
Pages	1540-1546
Number of pages	7
Volume	38
DOIs	https://doi.org/10.1016/j.promfg.2020.01.132
Publication status	Published - 2019
MoE publication type	A4 Conference publication
Event	International Conference on Flexible Automation and Intelligent Manufacturing - Limerick, Ireland Duration: 24 Jun 2019 → 28 Jun 2019 Conference number: 29

Publication series

Name	Procedia Manufacturing
Publisher	Elsevier
ISSN (Electronic)	2351-9789

Conference

Conference	International Conference on Flexible Automation and Intelligent Manufacturing
Abbreviated title	FAIM
Country/Territory	Ireland
City	Limerick
Period	24/06/2019 → 28/06/2019

Keywords

ultrasonic burnishing
tangential misalignment
surface integrity

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10.1016/j.promfg.2020.01.132Licence: CC BY-NC-ND

Huuki_et_al_Effect_of_tangential_Procedia_ManufacturingFinal published version, 804 KBLicence: CC BY-NC-ND

Cite this

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title = "Effect of tangential misalignment in ultrasonic burnishing",

abstract = "Ultrasonic burnishing is a surface finishing process that produces fine surface roughness, improved geometrical accuracy, high compressive residual stresses and increased hardness. The method is suitable for finishing dies or other double curvature surfaces and it does not require changing of the fixturing setup after a machining process. The method has not however become commonly used in industry, because the technology has not been extensively tested. Technological parameters in ultrasonic burnishing includes the surface speed, distance between consecutive passes (or in machining terms, feed) and contact force. Ultrasonic burnishing is based on forging at an ultrasonic frequency of over 20,000 impacts per second and there is no material removal associated with the process. The technological parameters have been tested and recommended values have been recorded for some common work materials. One important parameter is the tangential alignment of the burnishing tool in regard to the workpiece surface normal. This parameter is easy to control in turning operations or with planar surfaces, but with a double curved surface the control of the angle is more difficult. All the previous research has been done on cylindrical or planar workpiece and therefore the tangential misalignment or the sensitivity of the surface integrity regarding the tangential misalignment has not been studied. This paper investigates the effect of the tangential misalignment of the burnishing tool and the effect on surface integrity. The results show that ultrasonic burnishing is suitable method for finishing workpiece surfaces even with inclined tool angle. The ultrasonic burnishing produced a beneficial surface integrity state on the workpiece surface with hardened material and improved surface quality. The surface micro-hardness increased by 1.4-6.7 %. At the same time, the average surface roughness (Ra) values decreased by 50-85 % depending on the misalignment angle. Previous article in issue",

keywords = "ultrasonic burnishing, tangential misalignment, surface integrity",

author = "Juha Huuki and Laakso, {Sampsa V. A.} and Rizwan Ullah",

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language = "English",

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booktitle = "29th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM2019), June 24-28, 2019, Limerick, Ireland",

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note = "International Conference on Flexible Automation and Intelligent Manufacturing, FAIM ; Conference date: 24-06-2019 Through 28-06-2019",

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Huuki, J, Laakso, SVA & Ullah, R 2019, Effect of tangential misalignment in ultrasonic burnishing. in 29th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM2019), June 24-28, 2019, Limerick, Ireland. vol. 38, Procedia Manufacturing, Elsevier, pp. 1540-1546, International Conference on Flexible Automation and Intelligent Manufacturing, Limerick, Ireland, 24/06/2019. https://doi.org/10.1016/j.promfg.2020.01.132

Effect of tangential misalignment in ultrasonic burnishing. / Huuki, Juha; Laakso, Sampsa V. A.; Ullah, Rizwan.
29th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM2019), June 24-28, 2019, Limerick, Ireland. Vol. 38 Elsevier, 2019. p. 1540-1546 (Procedia Manufacturing).

Research output: Chapter in Book/Report/Conference proceeding › Conference article in proceedings › Scientific › peer-review

TY - GEN

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AU - Laakso, Sampsa V. A.

AU - Ullah, Rizwan

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PY - 2019

Y1 - 2019

N2 - Ultrasonic burnishing is a surface finishing process that produces fine surface roughness, improved geometrical accuracy, high compressive residual stresses and increased hardness. The method is suitable for finishing dies or other double curvature surfaces and it does not require changing of the fixturing setup after a machining process. The method has not however become commonly used in industry, because the technology has not been extensively tested. Technological parameters in ultrasonic burnishing includes the surface speed, distance between consecutive passes (or in machining terms, feed) and contact force. Ultrasonic burnishing is based on forging at an ultrasonic frequency of over 20,000 impacts per second and there is no material removal associated with the process. The technological parameters have been tested and recommended values have been recorded for some common work materials. One important parameter is the tangential alignment of the burnishing tool in regard to the workpiece surface normal. This parameter is easy to control in turning operations or with planar surfaces, but with a double curved surface the control of the angle is more difficult. All the previous research has been done on cylindrical or planar workpiece and therefore the tangential misalignment or the sensitivity of the surface integrity regarding the tangential misalignment has not been studied. This paper investigates the effect of the tangential misalignment of the burnishing tool and the effect on surface integrity. The results show that ultrasonic burnishing is suitable method for finishing workpiece surfaces even with inclined tool angle. The ultrasonic burnishing produced a beneficial surface integrity state on the workpiece surface with hardened material and improved surface quality. The surface micro-hardness increased by 1.4-6.7 %. At the same time, the average surface roughness (Ra) values decreased by 50-85 % depending on the misalignment angle. Previous article in issue

AB - Ultrasonic burnishing is a surface finishing process that produces fine surface roughness, improved geometrical accuracy, high compressive residual stresses and increased hardness. The method is suitable for finishing dies or other double curvature surfaces and it does not require changing of the fixturing setup after a machining process. The method has not however become commonly used in industry, because the technology has not been extensively tested. Technological parameters in ultrasonic burnishing includes the surface speed, distance between consecutive passes (or in machining terms, feed) and contact force. Ultrasonic burnishing is based on forging at an ultrasonic frequency of over 20,000 impacts per second and there is no material removal associated with the process. The technological parameters have been tested and recommended values have been recorded for some common work materials. One important parameter is the tangential alignment of the burnishing tool in regard to the workpiece surface normal. This parameter is easy to control in turning operations or with planar surfaces, but with a double curved surface the control of the angle is more difficult. All the previous research has been done on cylindrical or planar workpiece and therefore the tangential misalignment or the sensitivity of the surface integrity regarding the tangential misalignment has not been studied. This paper investigates the effect of the tangential misalignment of the burnishing tool and the effect on surface integrity. The results show that ultrasonic burnishing is suitable method for finishing workpiece surfaces even with inclined tool angle. The ultrasonic burnishing produced a beneficial surface integrity state on the workpiece surface with hardened material and improved surface quality. The surface micro-hardness increased by 1.4-6.7 %. At the same time, the average surface roughness (Ra) values decreased by 50-85 % depending on the misalignment angle. Previous article in issue

KW - ultrasonic burnishing

KW - tangential misalignment

KW - surface integrity

U2 - 10.1016/j.promfg.2020.01.132

DO - 10.1016/j.promfg.2020.01.132

M3 - Conference article in proceedings

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T3 - Procedia Manufacturing

SP - 1540

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BT - 29th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM2019), June 24-28, 2019, Limerick, Ireland

PB - Elsevier

T2 - International Conference on Flexible Automation and Intelligent Manufacturing

Y2 - 24 June 2019 through 28 June 2019

ER -

Effect of tangential misalignment in ultrasonic burnishing

Abstract

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Keywords

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