Using the FEM Method in the Prediction of Stress and Deformation in the Processing Zone of an Elastic/Visco-Plastic Material during Diamond Sliding Burnishing
Source abstract
Abstract
This article concerns the application of the FEM method for the prediction of stress and deformation states in the workpiece during diamond sliding burnishing (DSB). An updated Lagrange (UL) description was used to describe the phenomena at a typical incremental step. The states of strain and strain rate are described by non-linear relationships without linearization. The material parameters were estimated during tensile tests to determine the characteristics of the 41Cr4 steel. Its hardness was also tested. Its aim was to prepare a table with the material properties of the above-mentioned steel and its implementation for numerical analyses. A Cowper–Symonds material model was used to model the displacement process of the wedge on an elastic/visco-plastic body reflecting the DSB process. The computer model was validated, and a good convergence of the results was obtained. Applications in the ANSYS/LS-Dyna program were developed to simulate the process of DSB. The results of numerical analyses were presented, among others, to explain the influence of the rake angle on the condition of the surface after machining, as well as the phenomenon of chip formation. The results of numerical simulations were verified experimentally on a test stand.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Advanced machining processes and optimization · Surface Treatment and Residual Stress · Advanced Surface Polishing Techniques
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Branch of the Koszalin University of Technology in Szczecinek, Faculty of Wood Industry, Koszalin University of Technology, Waryńskiego 1 Street, 78-400 Szczecinek, Poland
Faculty of Mechanical Engineering, Koszalin University of Technology, Racławicka 15-17 Street, 75-620 Koszalin, Poland
Faculty of Mechanical Engineering, Kazimierz Pulaski University of Technology and Humanities in Radom, 54 Stasieckiego Street, 26-600 Radom, Poland
Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, Al. Powst. Warszawy 8, 35-959 Rzeszów, Poland
Department of Ship Electroenergetic Systems, National University of Shipbuilding Named after Admiral Makarov, Heroiv Stalinhradu Ave 9, 54025 Mykolaiv, Ukraine
References (90)
Show source-provided references
1. Gryglicki, R., and Kukiełka, L. (2008). Contemporary Problems in Burnishing Processing Technology, TON’2008.
2. Przybylski, W. (1987). Burnishing Technology, WNT.
3. Torbilo, V.M. (1974). Almaznoe Vyglażivanie, Masinostrojenie.
4. Biezuchov, N.I. (1957). Theory of Elasticity and Plasticity, PWN.
5. Jezierski, J., Mazur, T., Siemiątkowski, Z., and Kowalik, M. (2005). Contemporary Problems in Burnishing Processing Technology, Publishing House of the Gdansk University of Technology.
6. An investigation of surface roughness of burnished AlSi 1042 steel
7. Korzyński, M. (1991). Optimalnyje Znaćenia Natjagu Pri Almaznomu Vyglaźivani Sfericeskim Nakonećnikom, Lvivski Politechnićeski Institut. Visnik Lvivskogo Politechnićeskogo Instituta nr 225.
8. Kudriavcev, I.V. (1965). Povysenie Dolgovecnosti Detalej Masin Metodom Poverhnostnogo Naklepa, Maśgiz.
9. Ultraprecision metal removal processing of mirror-surfaces10.1016/S0924-0136(00)00844-X ↗
10. Odincov, L.T. (1981). Finisnaja Obrabotka Detalej Vyglazyvaniem i Almaznym Vyglazyvaniem, Masinostrojenie.
11. Kragielski, I.V. (1968). Trenie i Iznos, Maśinostrojenie.
12. Burnishing force and number of ball passes for the optimum surface finish of brass components10.1016/S0924-0136(98)00058-2 ↗
13. Przybylski, W. (2005). Modern Problems in Burnishing Treatment Technology, Publishing House of the Gdansk University of Technology.
14. The effects of initial burnishing parameters on non-ferrous components10.1016/S0924-0136(00)00464-7 ↗
15. Numerical Study of the Influence of Surface Regular Asperities Prepared in Previous Treatment by Embossing Process on the Object Surface Layer State after Burnishing10.4028/www.scientific.net/AMM.474.448 ↗
16. Modelling of initial and boundary problems with geometrical and physical nonlinearity and its application in burnishing processes
17. Patyk, R., Kukielka, L., Kaldunski, P., Bohdal, L., Chodor, J., Kulakowska, A., Kukielka, K., and Nagnajewicz, S. (2018). AIP Conference Proceedings, AIP Publishing LLC.
18. Patyk, S., Patyk, R., Kukielka, L., Kaldunski, P., and Chojnacki, J. (2017). Numerical method for determining the main force of burnishing rolling of rough cylindrical surface with regular periodical outlines asperities. Eng. Mech., 754–757.
19. Effects of working parameters on surface finish in ball-burnishing of hardened steel10.1016/j.precisioneng.2004.02.002 ↗
20. Determination of optimal ball-burnishing parameters for plastic injection moulding steel
21. Effect of Toller burnishing on the high cycle fatique performance of the high-strength wrought magnesium alloy AZ8010.1016/j.scriptamat.2005.01.026 ↗
22. Szulc, S., and Stefko, A. (1976). Surface Treatment of Machine Parts, WNT.
23. The influence of surface enhancement by low plasticity burnishing on the corrosion fatique performance of AA7075-T610.1016/j.ijfatigue.2004.01.010 ↗
24. Tubielewicz, K., and Zaborski, A. Modeling and Experimental Analysis of the Deformation Process during Burnishing and Wear. Proceedings of the 7th Scientific and Technical Conference “Burnishing Processing Technology”, Bydgoszcz, Poland.
25. Modeling and experimental validation of the force–surface roughness relation for smoothing burnishing with a spherical tool10.1016/j.ijmachtools.2007.03.002 ↗
26. Evaluation of the staircase and the accelerated test methods for fatigue limit distributions10.1016/S0142-1123(00)00039-6 ↗
27. Fatigue strength of chromium coated elements and possibility of its improvement with slide diamond burnishing10.1016/j.surfcoat.2008.12.022 ↗
28. Influence of shot peening and hard chromium electroplating on the fatigue strength of 7050-T7451 aluminum alloy10.1016/j.ijfatigue.2006.10.003 ↗
29. Influence of shot peening on bending tooth fatigue limit of case hardened gears10.1016/S0142-1123(02)00034-8 ↗
30. Improvement in fatigue strength of 41Cr4 steel through slide diamond burnishing10.1007/s40430-020-02276-8 ↗
31. Skalski, K., and Jezierski, J. Analysis of the Depth of Plastic Deformation in Surface Treatment with Burnishing. Proceedings of the 3rd Scientific and Technical Conference “Burnishing Processing Technology”, Bydgoszcz, Poland.
32. Slide diamond burnishing influence on of surface stereometric structure of an AZ91 alloy10.1016/j.surfcoat.2016.09.045 ↗
33. Quality improvement of ball-end milled sculptured surfaces by ball burnishing10.1016/j.ijmachtools.2005.03.007 ↗
34. Tubielewicz, K., Major, B., and Zaborski, A. The Structure of the Surface Layer After Burnishing. Proceedings of the 7th Scientific and Technical Conference “Burnishing Processing Technology”, Bydgoszcz, Poland.
35. Zdrodowski, S. (2002). A Summary of the Runout Test Results of the Measurement Paths on the Old and New Borsig Compressor Rotor Shaft, Przedsiębiorstwo Remontowe Maszyn i Armature Masz-ZAP. Report on Work for Przedsiębiorstwo Remontowe Maszyn i Armature Masz-ZAP.
36. Precision surface finish of the mold steel PDS5 using an innovative ball burnishing tool embedded with a load cell10.1016/j.precisioneng.2009.03.003 ↗
37. Patyk, S., Patyk, R., and Kukiełka, L. (2008). Contemporary Problems in Burnishing Processing Technology, TON’2008.
38. Patyk, S., Patyk, R., and Kukiełka, L. (2008). Contemporary Problems in Burnishing Processing Technology, TON’2008.
39. Świrad, S., and Dudek, K. (2008). Contemporary Problems in Burnishing Processing Technology, TON’2008.
40. Sznejder, U.G. (1972). Obrazowanie Regularnych Mikrorelefov na Detalach i Ich Eksplatacjonnyje Svojstva, Maszinostrojenie.
41. Laser-assisted burnishing of metals10.1016/j.ijmachtools.2006.03.002 ↗
42. Surface layer characteristics due to slide diamond burnishing with a cylindrical-ended tool10.1016/j.jmatprotec.2010.08.029 ↗
43. Effect of machining parameters on surface properties in slide diamond burnishing of aluminum matrix composites10.1016/j.matpr.2015.05.033 ↗
44. Inflence of finishing by burnishing on surface characteristics10.1361/105994903770343457 ↗
45. Infuence of slide burnishing process on the surface characteristics of precipitation hardenable steel10.1007/s42452-021-04260-w ↗
46. Kleiber, M. (1998). Handbook of Computational Solid Mechanics. Survey and Comparison of Contemporary Methods, Springer.10.1007/978-3-642-80396-3 ↗
47. Burczyński, T. (1995). Boundary Element Method in Mechanics, WNT.
48. Kleiber, M. (1989). Introduction to the Finite Element Method, PWN.
49. Kleiber, M. (1985). Finite Element Method in Non-Linear Continuum Mechanics, PWN.
50. Zienkiewicz, O.C., and Taylor, R.L. (2000). The Finite Element Method. Volume 1—The Basis, Butterworth—Heinemann.
51. Zienkiewicz, O.C., and Taylor, R.L. (2000). The Finite Element Method. Volume 2—Solid Mechanics, Butterworth—Heinemann.
52. Zienkiewicz, O.C., and Taylor, R.L. (2000). The Finite Element Method. Volume 3—Fluid Dynamics, Butterworth—Heinemann.
53. Belytschko, T., Liu, W.K., and Moran, B. (2000). Nonlinear Finite Elements for Continua and Structures, John Wiley & Sons.
54. Liu, G.R., and Liu, M.B. (2003). A Meshfree Particle Method, World Scientific.
55. Jach, K. (2001). Computer Modeling of Dynamic Interactions of Bodies Using the Free Point Method, PWN.
56. A particle-in-cell solution to the silo discharging problem10.1002/(SICI)1097-0207(19990730)45:9<1203::AID-NME626>3.0.CO;2-C ↗
57. The material point method in large strain engineering problems10.1016/j.cma.2004.01.035 ↗
58. Orkisz, J. (2005, January 21–24). Recent advances in meshless finite difference methods. Proceedings of the CMM-2005—Computer Methods in Mechanics, Częstochowa, Poland.
59. FLAC (1995). Fast Lagrangian Analysis of Continua, Itasca.
60. Bathe, K.J. (1982). Finite Element Procedures in Engineering Analisis, Prentice—Hall.
61. Burakowski, T., and Wierzchoń, T. (1995). Metal Surface Engineering, WNT.
62. A finite point method in computational mechanics. Applications to convective transport and fluid flow10.1002/(SICI)1097-0207(19961130)39:22<3839::AID-NME27>3.0.CO;2-R ↗
63. Element-free Galerkin method10.1002/nme.1620370205 ↗
64. SPH simulations of magnetic fields in galaxy clusters
65. Chodor, J., and Kukielka, L. (2014). Applied Mechanics and Materials, Trans Tech Publications Ltd.
66. Chodor, J., and Zurawski, L. (2016). Advances in Mechanics: Theoretical, Computational and Interdisciplinary Issues, CRC Press.
67. A possibility of application of mtdil to the residual stresses analysis the hard coating—Substrate system10.1023/B:JTAN.0000033210.69839.5e ↗
68. Application of variational and FEM methods to the modelling and numerical analysis of the slitting process for geometrical and physical nonlinearity10.15632/jtam-pl.53.2.487 ↗
69. Application of variational and FEM methods to the modelling and numerical analysis of guillotining process for geometrical and physical nonlinearity10.5755/j01.mech.20.2.6941 ↗
70. Modelling and experimental analysis of shear-slitting process of light metal alloys using FEM, SPH and vision-based methods10.1063/1.5092063 ↗
71. Analysis of Slitting of Aluminum Body Panels in the Aspect of Scrap Reduction
72. Three Dimensional Finite Element Simulation of Sheet Metal Blanking Process10.4028/www.scientific.net/AMM.474.430 ↗
73. Kukielka, K., Kukielka, L., Bohdal, L., Kulakowska, A., Malag, L., and Patyk, R. (2014). Applied Mechanics and Materials, Trans Tech Publications Ltd.
74. Kukiełka, L. (2001). Computational and Experimental Methods, WITPRESS.
75. New damping models of metallic materials and its application in non-linear dynamical cold processes of metal forming
76. Kukiełka, L., Geleta, K., and Kukiełka, K. (2012). Steel Research International, Wiley-VCH Verlag GmbH & Co. KGaA.
77. A method of increasing the depth of the plastically deformed layer in the roller burnishing process10.1063/1.5034865 ↗
78. Kowalik, M., Trzepieciński, T., Kukiełka, L., Paszta, P., Maciąg, P., and Legutko, S. (2021). Experimental and numerical analysis of the depth of the strengthened layer on shafts resulting from roller burnishing with roller braking moment. Materials, 14.10.3390/ma14195844 ↗
79. Numerical Analysis and Simulation of Drawpiece Forming Process by Finite Element Method10.4028/www.scientific.net/AMM.474.153 ↗
80. Numerical analysis of the deep drawing process including the history of stress and strain
81. Kaldunski, P., Kukielka, L., Patyk, R., Kulakowska, A., Bohdal, L., Chodor, J., and Kukielka, K. (2018). Study of the Influence of Selected Anisotropic Parameter in the Barlat’s Model on the Drawpiece Shape, AIP Publishing LLC.10.1063/1.5035040 ↗
82. Numerical analysis of states of strain and stress of material during machining with a single abrasive grain
83. Miksza, M., Bohdal, Ł., Kałduński, P., Patyk, R., and Kukiełka, L. (2022). Forecasting the Fatigue Strength of DC01 Cold-Formed Angles Using the Anisotropic Barlat Model. Materials, 15.10.3390/ma15238436 ↗
84. Investigation of Condensing Heating Surfaces with Reduced Corrosion of Boilers with Water-Fuel Emulsion Combustion10.1007/978-3-030-66717-7_25 ↗
85. Horajski, P., Bohdal, L., Kukielka, L., Patyk, R., Kaldunski, P., and Legutko, S. (2021). Advanced Structural and Technological Method of Reducing Distortion in Thin-Walled Welded Structures. Materials, 14.10.3390/ma14030504 ↗
86. Ti3SiC2 as a Bonding Phase in Diamond Composites10.1023/A:1012535100330 ↗
87. (2002). Metallic materials—Tensile testing—Part 1: Method of test at ambient temperature (Standard No. EN 10002-1+AC1 standard).
88. Plane-Stress Fracture Toughness Testing Using a Crack-Line-Loaded Specimen10.1016/0013-7944(72)90053-7 ↗
89. ANSYS (2007). Theory Reference 11.0, Ansys Inc.
90. Kukiełka, L. (2002). Fundamentals of Engineering Studies, PWN. (in Polish).