scholarly journals Enhancing Surface Topology of Udimet®720 Superalloy through Ultrasonic Vibration-Assisted Ball Burnishing

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 915 ◽  
Author(s):  
Ramón Jerez-Mesa ◽  
Victoria Plana-García ◽  
Jordi Llumà ◽  
J. Antonio Travieso-Rodriguez
Keyword(s):  
Ultrasonic Vibration ◽  
Influential Factors ◽  
Surface Topology ◽  
Topological Descriptors ◽  
Transportation Industry ◽  
Ball Burnishing ◽  
Ultrasonic Assisted ◽  
Burnishing Process ◽  
Mechanical Performances ◽  
Number Of Passes

This contribution reports the effects of an ultrasonic-vibration assisted ball burnishing process on the topological descriptors of nickel-based alloy Udimet®720. This material is of high interest for the transportation industry, and specifically for the aeronautical sector. Despite the acknowledged necessity to finish this material to achieve excelling mechanical performances of parts, surface integrity enhancement by means of plastic deformation through ball burnishing has seldom been explored in previous references so far. In this paper, different surface descriptors are used to report how the topology changes after ultrasonic-assisted ball burnishing, and how burnishing conditions influence that change. The burnishing preload and the number of passes are the only influential factors on surface change, whereas the feed velocity of the tool and the strategy reveal not to be relevant on the result. Additionally, the extent to which the process successfully modifies the objective surfaces is highly divergent depending on the original scale of the treated surface. The assistance of the process with vibrations also shows that the resulting topologies are characterized by a periodical pattern of repetitive peaks and valleys that are extended on the surface with a higher frequency in comparison to the non-assisted process, which could influence in the functional deployment of workpieces treated through it, and could deliver an advantage with regard to its non-assisted homologous process.

scholarly journals Combination of Acoustic Emission and Vibratory Measurements to Characterize an Ultrasonic Vibration Assisted Ball Burnishing Tool for a Lathe

2021 ◽  
Author(s):  
Ismael Fernández-Osete ◽  
Aida Estevez-Urra ◽  
Eric Velázquez-Corral ◽  
David Valentin ◽  
Jordi Llumà ◽  
...  
Keyword(s):  
Acoustic Emission ◽  
Ultrasonic Vibration ◽  
Numerical Control ◽  
Resonance Problem ◽  
Ultrasonic Frequency ◽  
Ball Burnishing ◽  
Burnishing Process ◽  
Vibration Assistance ◽  
Low Amplitude

In this paper, a resonant system that produces a movement of low amplitude and ultrasonic frequency is used to achieve the vibration assistance in a ball-burnishing process. A full vibration characterization of this process performed in a lathe was done. It is carried out by a new tool designed in the research group of the authors. Its purpose is to demonstrate that the machine and the tool do not have any resonance problem during the process and to prevent possible failures. The analysis of this dynamic behaviour permits to validate the suitability of the tool when it is anchored to a numerical control lathe. This is very important for its future industrial implementation. It is also intended to confirm that the system adequately transmits vibrations through the material. To do this, a methodology to validate the dynamic tool behaviour was developed. Several techniques that combine the usual and ultrasonic vibration ranges through static and dynamic measurements were merged: vibration and acoustic emission measurements. An operational deflection shape (ODS) exercise has been also performed. Results show the suitability of the tool used to transmit the assistance vibrations, and that no damage is produced in the material in any case.

Optimization of the Surface Roughness and Superficial Hardness Improvement Using the Hybrid Grey-Based Taguchi Method for the Small Ball-Burnishing Process of STAVAX

2015 ◽  
Vol 649 ◽  
pp. 112-119
Author(s):  
Quoc Nguyen Banh ◽  
Fang Jung Shiou
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Process Condition ◽  
Surface Hardness ◽  
Principal Component ◽  
Ball Burnishing ◽  
Small Ball ◽  
Burnishing Process ◽  
Step Over ◽  
Number Of Passes

This study aims to optimize the small ball-burnishing process parameters in order to simultaneously improve the surface roughness and superficial surface hardness of the STAVAX material. A newly developed load cell embedded double spring mechanism burnishing tool was designed and fabricated. By utilizing the hybrid grey-based Taguchi method with principal component analysis (PCA) and entropy measurement the optimal process condition was the combination of the burnishing force at 10 N, the step-over at 6 μm, the number of passes at 3 times, the grease for lubricant, and the burnishing speed at 500 mm/min. The burnishing force, step-over, and the number of passes were found to have the main effects on the burnished surfaces among the five chosen control factors. The burnished surface of STAVAX material under the optimal condition was improved from Ra 0.85 to Ra 0.079 for average surface roughness, and from 67.3 HR30N to 72.7 HR30N in term of superficial hardness.

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

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5746
Author(s):  
Ismael Fernández-Osete ◽  
Aida Estevez-Urra ◽  
Eric Velázquez-Corral ◽  
David Valentin ◽  
Jordi Llumà ◽  
...  
Keyword(s):  
Acoustic Emission ◽  
Ultrasonic Vibration ◽  
Vibration Measurement ◽  
Ultrasonic Frequency ◽  
Emission Measurement ◽  
Ball Burnishing ◽  
Burnishing Process ◽  
Dynamic Techniques ◽  
Vibration Assistance ◽  
Low Amplitude

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.

scholarly journals Monitoring of Processing Conditions of an Ultrasonic Vibration-Assisted Ball-Burnishing Process

Sensors ◽  
2020 ◽  
Vol 20 (9) ◽  
pp. 2562 ◽  
Author(s):  
Aida Estevez-Urra ◽  
Jordi Llumà ◽  
Ramón Jerez-Mesa ◽  
Jose Antonio Travieso-Rodriguez
Keyword(s):  
Ultrasonic Vibration ◽  
Natural Frequencies ◽  
Milling Machine ◽  
Processing Conditions ◽  
Mechanical Assembly ◽  
Ball Burnishing ◽  
Beneficial Effects ◽  
Burnishing Process ◽  
Vibration Assistance ◽  
Vibratory Signals

Although numerous references present the beneficial effects on surface integrity of ultrasonic vibration-assisted ball burnishing (UVABB), nothing has been reported about the dynamic behavior of the UVABB tool, workpiece, and machine triad during the process. In this paper, a dynamic monitorization through a set of 5 accelerometers is tested to analyze the interactions between the tool–workpiece–machine mechanical assembly. A UVABB tool attached to a milling machine and equipped with a piezoelectric stack that is able to assist the process with a 40-kHz vibration is tested on a milled C45 steel surface. First, the natural frequencies of the mechanical system are obtained through hammer impact tests. Then, the vibratory signals transmitted during the execution of the process are monitored and compared to those: two feed velocities and two burnishing preloads, all with and without vibration-assistance. Results show that the proposed accelerometer set is valid to assess the behavior of a UVABB process. The system’s natural frequencies are not varied by vibration-assistance and are not excited when the piezoelectric is functioning. It is confirmed that UVABB is safe for the machine and the tool, and there is no unexpected excited frequencies due to the piezoelectric excitation.

scholarly journals Ultrasound Effect on the Microstructure and Hardness of AlMg3 Alloy under Upsetting

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 1010
Author(s):  
Przemysław Snopiński ◽  
Tibor Donič ◽  
Tomasz Tański ◽  
Krzysztof Matus ◽  
Branislav Hadzima ◽  
...  
Keyword(s):  
Flow Stress ◽  
Ultrasonic Vibration ◽  
Light And Electron Microscopy ◽  
Load Flow ◽  
Forming Limit ◽  
Ultrasonic Vibrations ◽  
Softening Effect ◽  
Simultaneous Application ◽  
Ultrasonic Assisted ◽  
Acoustic Softening

To date, numerous investigations have shown the beneficial effect of ultrasonic vibration-assisted forming technology due to its influence on the forming load, flow stress, friction condition reduction and the increase of the metal forming limit. Although the immediate occurring force and mean stress reduction are known phenomena, the underlying effects of ultrasonic-based material softening remain an object of current research. Therefore, in this article, we investigate the effect of upsetting with and without the ultrasonic vibrations (USV) on the evolution of the microstructure, stress relaxation and hardness of the AlMg3 aluminum alloy. To understand the process physics, after the UAC (ultrasonic assisted compression), the microstructures of the samples were analyzed by light and electron microscopy, including the orientation imaging via electron backscatter diffraction. According to the test result, it is found that ultrasonic vibration can reduce flow stress during the ultrasonic-assisted compression (UAC) process for the investigated aluminum–magnesium alloy due to the acoustic softening effect. By comparing the microstructures of samples compressed with and without simultaneous application of ultrasonic vibrations, the enhanced shear banding and grain rotation were found to be responsible for grain refinement enhancement. The coupled action of the ultrasonic vibrations and plastic deformation decreased the grains of AlMg3 alloy from ~270 μm to ~1.52 μm, which has resulted in a hardness enhancement of UAC processed sample to about 117 HV.

scholarly journals Improving the Surface Finish of Concave and Convex Surfaces Using a Ball Burnishing Process

2011 ◽  
Vol 26 (12) ◽  
pp. 1494-1502 ◽  
Author(s):  
J. A. Travieso-Rodríguez ◽  
G. Dessein ◽  
H. A. González-Rojas
Keyword(s):  
Surface Finish ◽  
Ball Burnishing ◽  
Convex Surfaces ◽  
Burnishing Process
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