This paper presents and discusses the conditions for the pre-machining and for the subsequent burnishing-rolling processes that ensure a very-high-quality product. Dependencies have been derived for the field areas of the contact of the burnishing element with the rough surface of an object made of work-hardening material.
The prime objective of the presently reported work is to assess the accuracy of the finite-element modelling of three-dimensional metal-forming processes, where the block-compression process has been chosen for experimental substantiation of the results of the theoretical model. A three-dimensional rigid-plastic finite-element approach has been used to simulate the metal flow during compression and the results of calculations of the strain distribution are compared with the strains measured during the compression of lead samples. Discrepancies between the calculations and the measurements are discussed in the paper and their sources are analyzed. The conclusion is drawn that the experimental verification of the results of the three-dimensional rigid-plastic finite-element method shows the high accuracy of the latter and confirms its ability to simulate metal-forming processes.
Burnishing is a plastic deformation process in which the asperities of a machined surface are depressed to give a smooth and workhardened surface. In this paper, the development of a roller type burnishing tool is reported together with some experimental results concerning roughness and microhardness of surfaces of alloyed aluminium components.
Prior research (ref. 1) reported a model to predict surface roughness for specified values of cutting tool nose radius, feed rate, cutting speed and tool wear. The model is based on experimental data from finish turning of gray cast iron using uncoated tungsten carbide inserts. The results suggest that feed rate and cutting speed can be modified to produce a specified surface roughness in the presence of increasing levels tool wear.
The method used in the paper to calculate values of feed rate and cutting speed is based on a multiple objective goal programming optimization scheme. The method predicts optimal machining conditions under the conflicting objectives of maximal production rate and minimal cost, subject to realistic constraints imposed by the capability of the machine tool and restrictions on the process parameters. Further adjustment of the cutting parameters is then made based on specified values of surface roughness and levels of tool wear.
An approach considering alternate routing for designing cellular manufacturing systems is presented. Alternate routing in automated manufacturing of families of parts is encountered in many real life situations. This aspect in the design of cellular manufacturing systems is not adequately handled. Therefore, a mathematical programming approach with an example problem is presented in the paper.
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