Evaluation of Surface Roughness of Burnished Dual-Phase Steels using Experimental and Finite Element Methods

Abstract

Surface finish has vital influence on most of functional properties of a component like fatigue life, wear resistance, corrosion resistance etc. A good surface finish is essential in many applications e.g. in the mould dies, bio engineering and optical industries. This has given birth to processes like lapping, honing, burnishing etc. Burnishing is a fine finishing operation involving the cold working plastic deformation of surface layers to enhance the surface integrity and the functional utility of a component. It is a simple and economical process and can be effectively used in aerospace industries, automobile manufacturing industries, production of machine tools etc. The present study has been carried out to establish the effect of burnishing parameters viz. feed rate, speed, force, ball diameter and lubricant on surface roughness of high strength low alloy (HSLA) dual – phase steel specimens. The result indicates that burnishing parameters have significant effect on the surface roughness. The improvement in surface roughness is with good agreement with the available literature. In the present work, stresses at various points of surface irregularities and deformation of surface layer upto certain depth, were calculated by FEM. The surface roughness values of FEA were compared with the experimental values