Effects of roller burnishing process parameters on surface
roughness of A356/5%SiC composite using response surface
methodology

doi:10.1007/s40436-014-0083-0

Advances in Manufacturing ›› 2014, Vol. 2 ›› Issue (4): 303-317.doi: 10.1007/s40436-014-0083-0

Effects of roller burnishing process parameters on surface roughness of A356/5%SiC composite using response surface methodology

Shashi Prakash Dwivedi, Satpal Sharma, Raghvendra Kumar Mishra

Gautam Buddha University, Greater Noida, Gautam Budh Nagar, U.P. 201310, India

收稿日期:2013-10-03 出版日期:2014-12-25 发布日期:2014-12-25
通讯作者: e-mail: shashi_gla47@rediffmail.com
作者简介:e-mail: shashi_gla47@rediffmail.com

Effects of roller burnishing process parameters on surface roughness of A356/5%SiC composite using response surface methodology

Shashi Prakash Dwivedi, Satpal Sharma, Raghvendra Kumar Mishra

Gautam Buddha University, Greater Noida, Gautam Budh Nagar, U.P. 201310, India

Received:2013-10-03 Online:2014-12-25 Published:2014-12-25
Contact: e-mail: shashi_gla47@rediffmail.com
About author:e-mail: shashi_gla47@rediffmail.com

摘要/Abstract

摘要： In this study, a simple roller burnishing tool was made to operate burnishing processes on A356/5%SiC metal matrix composite fabricated by electromagnetic stir casting under different parameters. The effects of burnishing speed, burnishing force and number of burnishing passes on the surface roughness and tribological properties were measured. Scanning electron microscopy (SEM) graphs of themachined surface with PCD (insert-10) tool and roller burnished surface with tungsten carbide (WC) roller were taken into consideration to observe the surface finish of metal matrix composites. The mechanical properties (tensile strength, hardness, ductility) of A356/5%SiC metal matrix composites were studied for both unburnished samples and burnished samples. The results revealed that the roller burnished samples of A356/ 5%SiC led to the improvement in tensile strength, hardness and ductility. In order to find out the effects of roller burnishing process parameters on the surface roughness of A356/ 5%SiC metal matrix composite, response surface methodology (RSM) (Box–Behnken design) was used and a prediction model was developed relevant to average surface roughness using experimental data. In the range of process parameters, the result shows that roller burnishing speed increases, and surface roughness decreases, but on the other hand roller burnishing force and number of passes increase, and surface roughness increases. Optimum values of burnishing speed (1.5 m/s), burnishing force (50 N) and number of passes (2)during roller burnishing of A356/5%SiC metal matrix composite to minimize the surface roughness (predicted 1.232 lm) have been found out. There was only 5.03% error in the experimental andmodeled results of surface roughness.

关键词: Burnishing speed , Burnishing force , Response surface methodology (RSM) , Box–Behnken design , Desirability function

Abstract: In this study, a simple roller burnishing tool was made to operate burnishing processes on A356/5%SiC metal matrix composite fabricated by electromagnetic stir casting under different parameters. The effects of burnishing speed, burnishing force and number of burnishing passes on the surface roughness and tribological properties were measured. Scanning electron microscopy (SEM) graphs of themachined surface with PCD (insert-10) tool and roller burnished surface with tungsten carbide (WC) roller were taken into consideration to observe the surface finish of metal matrix composites. The mechanical properties (tensile strength, hardness, ductility) of A356/5%SiC metal matrix composites were studied for both unburnished samples and burnished samples. The results revealed that the roller burnished samples of A356/ 5%SiC led to the improvement in tensile strength, hardness and ductility. In order to find out the effects of roller burnishing process parameters on the surface roughness of A356/ 5%SiC metal matrix composite, response surface methodology (RSM) (Box–Behnken design) was used and a prediction model was developed relevant to average surface roughness using experimental data. In the range of process parameters, the result shows that roller burnishing speed increases, and surface roughness decreases, but on the other hand roller burnishing force and number of passes increase, and surface roughness increases. Optimum values of burnishing speed (1.5 m/s), burnishing force (50 N) and number of passes (2)during roller burnishing of A356/5%SiC metal matrix composite to minimize the surface roughness (predicted 1.232 lm) have been found out. There was only 5.03% error in the experimental andmodeled results of surface roughness.

Key words: Burnishing speed , Burnishing force , Response surface methodology (RSM) , Box–Behnken design , Desirability function

Shashi Prakash Dwivedi, Satpal Sharma, Raghvendra Kumar Mishra. Effects of roller burnishing process parameters on surface roughness of A356/5%SiC composite using response surface methodology[J]. Advances in Manufacturing, 2014, 2(4): 303-317.

参考文献

1. Yan BH, Wang CC, Chow HM et al (2000) Feasibility study of rotary electrical discharge machining with ball burnishing for Al2O3/6061Al composite. Int J Machine Tools Manuf 40(10): 1403–1421
2. Gharbi F, Sghaier S, Hamdi H et al (2012) Ductility improvement of Al 1050A rolled sheet by a newly designed ball burnishing tool device. Int J Adv Manuf Technol 60:87–99
3. Lopez de Lacalle LN, Lamikiz A, Sanchez JA et al (2007) The effect of ball burnishing on heat-treated steel and Inconel 718 milled surfaces. Int J Adv Manuf Technol 32:958–968
4. El-Axir MH (2000) An investigation into roller burnishing. Int J Machine Tools Manuf 40(11):1603–1617
5. El-Khabeery MM, El-Axir MH (2001) Experimental techniques for studying the effects of milling roller-burnishing parameters on surface integrity. Int J Machine Tools Manuf 41(12):1705–1719
6. Luo H, Liu J, Wang L, Zhong Q (2005) Investigation of the burnishing process with PCD tool on non-ferrous metals. Int J Adv Manuf Technol 25:454–459
7. Luo H, Liu J, Wang L, Wang Q (2006) The effect of burnishing parameters on burnishing force and surface microhardness. Int J Adv Manuf Technol 28:707–713
8. Luoa H, Liu J, Wang L, Zhong Q (2006) Study of the mechanism of the burnishing process with cylindrical polycrystalline diamond tools. J Mater Process Technol 180:9–16
9. Yeldose BC, Ramamoorthy B (2008) An investigation into the high performance of TiN-coated rollers in burnishing process.J Mater Process Technol 207:350–355
10. El-Taweel TA, El-Axir MH (2009) Analysis and optimization of the ball burnishing process through the Taguchi technique. Int J Adv Manuf Technol 41:301–310
11. Klocke F, Backer V, Wegner H et al (2009) Influence of process and geometry parameters on the surface layer state after roller burnishing of IN718. Prod Eng Res Dev 3:391–399
12. Franzen V, Trompeter M, Brosius A et al (2010) Finishing of thermally sprayed tool coatings for sheet metal forming operations by roller burnishing. Int J Mater Form 3(1):147–150
13. Aysun S (2011) Analysis and optimization of surface roughness in the ball burnishing process using response surface methodology and desirabilty function. Adv Eng Softw 42:992–998
14. Korzynski M, Lubas J, Swirad S et al (2011) Surface layer characteristics due to slide diamond burnishing with a cylindrical-ended tool. J Mater Process Technol 211:84–94
15. Swirad S (2011) The surface texture analysis after sliding burnishing with cylindrical elements. Wear 271:576–581
16. Tadic B, Todorovic PM, Luzanin O et al (2013) Using specially designed high-stiffness burnishing tool to achieve high-quality surface finish. Int J Adv Manuf Technol 67:601–611
17. Balland P, Tabourot L, Degre F et al (2013) An investigation of the mechanics of roller burnishing through finite element simulation and experiments. Int J Machine Tools Manuf 65:29–36
18. Balland P, Tabourot L, Degre F et al (2013) Mechanics of the burnishing process. Precis Eng 37:129–134
19. Dwivedi SP, Kumar S, Kumar A (2012) Effect of turning parameters on surface roughness of A356/5% SiC compositeproduced by electromagnetic stir casting. J Mech Sci Technol 26(12):3973–3979
20. Muralidharan R, Ramana GR (2013) Thermal plasma synthesis of SiC. Adv Manuf 1:50–61
21. Rao TB, Gopala Krishna A (2013) Simultaneous optimization of multiple performance characteristics in WEDM for machining ZC63/SiCp MMC. Adv Manuf 1:265–275
22. El-Tayeb NSM, Low KO, Brevern PV (2007) Influence of roller burnishing contact width and burnishing orientation on surface quality and tribological behaviour of Aluminium 6061. J Mater Process Technol 186:272–278
23. Dwivedi SP, Sharma S, Mishra K (2014) Microstructure and mechanical behavior of A356/SiC/Fly-ash hybrid composites produced by electromagnetic stir casting. J Braz Soc Mech Sci Eng 1–11
24. Wang G, Rong YM (2013) Advances of physics-based precision modeling and simulation for manufacturing processes. Adv Manuf 1:75–81
25. Chen SL, Cao WS, Zhang F et al (2013) Development of a computational tool for materials design. Adv Manuf 1:123–129
26. Kosaraju S, Anne VG (2013) Optimal machining conditions for turning Ti–6Al–4V using response surface methodology. Adv Manuf 1:329–339
27. Xu Y, Gao F, Zhang B et al (2013) Technology of self-repairing and reinforcement of metal worn surface. Adv Manuf 1:102–105
28. Lu WC, Ji XB, Li MJ et al (2013) Using support vector machine for materials design. Adv Manuf 1:151–159
29. Li FL, Xia W, Zhou ZY et al (2013) Analytical prediction and experimental verification of surface roughness during the burnishing process. Int J Machine Tools Manuf 62:67–75

Effects of roller burnishing process parameters on surface roughness of A356/5%SiC composite using response surface methodology

Effects of roller burnishing process parameters on surface roughness of A356/5%SiC composite using response surface methodology

PDF

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 1

编辑推荐

Metrics

本文评价