Surface improvement of shafts by the deep ball-burnishing technique

• Published in: Surface & coatings technology Vol. 206; no. 11-12; pp. 2817 - 2824
• Main Authors: Rodríguez, A., López de Lacalle, L.N., Celaya, A., Lamikiz, A., Albizuri, J.
• Format: Journal Article
• Language: English
• Published: Amsterdam Elsevier B.V 15.02.2012; Elsevier
• Subjects: Ball-burnishing; Cross-disciplinary physics: materials science; rheology; Exact sciences and technology; Hardness; Materials science; Physics; Residual stress; Rotating shafts; Surface quality; Surface treatments; Ball-burnishing; Surface quality; Hardness; Residual stress; Rotating shafts; Shafts; Quality; Burnishing; Surface treatments; Residual stresses; Surface states
• ISSN: 0257-8972; 1879-3347
• DOI: 10.1016/j.surfcoat.2011.11.045

In this article, deep ball-burnishing as a mechanical surface treatment for improving productivity and quality of rotating shafts is presented. When this technique is combined and applied after conventional turning, the resulting process is rapid, simple and cost-effective, directly applicable in lathes and turning centers of production lines. This process provides good surface finish, high compressive residual stresses, and hardness increment of the surface layer. These characteristics are the key for the fatigue life improvement of the component, and for wear resistance due to the higher hardness. This work presents a complete analysis of the principal beneficial aspects produced by the application of ball-burnishing. To determinate the influence of each process parameter, several tests were carried out. Once the optimum parameters were established, a complete analysis of the surface characteristics was performed. Surface topographies, sub-surface micro-hardness and residual stresses were measured. Complementary, a finite element model of ball-burnishing was used to understand and predict residual stress values and their variety with the process parameters. Results show that burnishing is an economical and feasible mechanical treatment for the quality improvement of rotating components, not only in surface roughness but in compressive residual stresses as well. ► Deep ball-burnishing for improve surface properties of AISI1045 turned parts. ► A full study of the influence of each parameter on the final surface-optimization. ► Surface and sub-surface characterization for optimum conditions. ► Increment of physical–mechanical properties of turned parts by ball-burnishing.