Comparative Study on Surface Finish in Cylindrical Grinding and Roller Burnishing Processes using Taguchi Methods

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1 International Journal of Production and Quality Engineering Copyright 2010 International Science Press Comparative Study on Surface Finish in Cylindrical Grinding and Roller Burnishing Processes using Taguchi Methods C. S. Jawalkar a, *, R. S. Walia a, Pradeep Kumar b and Inderdeep Singh b a Production Engineering Department, Punjab Engineering College, Chandigarh, India * csjawalkar@rediffmail.com b Indian Institute of Technology, Roorkee, India ISSN: Vol. 2, No. 1, January-June 2011, pp. 1-7 ABSTRACT Roller burnishing is a superior process of finishing. It is a cold forming process which gives better results than grinding. The process is used on previously machined or ground surfaces of cylindrical or conical in nature for both external and internal surfaces. It involves rubbing a smooth, hard object over the minute surface irregularities that are produced during machining or shearing. The hardened rolls of the tool press against the surface and deform the protrusions to a more nearly flat geometry. The burnishing process is an attractive technique which improves the surface integrity of the work-piece, i.e. surface finish and micro-hardness in a single process (with reduction in tool set-up time), which is difficult in conventional processes like grinding. This improvement in the surface integrity mainly serves to increase fatigue behaviour of work-pieces under dynamic loading. Through this paper the results of the experimental research on surface finish is discussed, with reference to roller burnishing and cylindrical grinding process on the EN-8 work pieces. Taguchi s parametric design strategy has been applied to investigate the effect of process parameters on surface roughness of both grinding and roller burnishing processes. Keywords: Cylindrical Grinding, Roller Burnishing, Surface Finish, Taguchi Techniques, Optimization. 1. INTRODUCTION In the roller burnishing process the increase in surface finish is achieved by flattening the rough peaks by compressive force of the rollers. It resembles metal forming or cold working in contrast to micro metal abrasion in the finishing processes like honing, lapping and super finishing. Two phenomena have been generally associated in the analysis of burnishing. One is flattening by plastic flow of roughness peaks and the second is their displacement into the adjacent valleys [1-3]. The latter appears to be an erroneous presumption due to the differential scaling of roughness heights and spacing, as well as of the roller diameter which together creates a distorted picture. In this type of cold working, several mechanisms are associated with these processes in view of the fact that brittle materials like C.I. also have been successfully burnished [4-6]. Keeping these factors in view, the major thrust in these investigations has been directed towards comprehensive analysis of surface integrity, prior to and after burnishing, since by its very definition the burnishing process is supposed to improve these characteristics. It is rather surprising that not many efforts have been made by the researchers in this direction. The roughness height distribution of normal engineering surfaces strongly suggest that different strata of the surfaces reflect in some way the results of different formative processes. A suitable analysis of their roughness size is therefore highly important in the analysis of mechanism of the formative processes [7-9]. In an experimental study carried out to study the effect of burnishing parameters (speed, depth, feed, burnishing radius and lathe) on surface roughness and waviness of non-ferrous components using theoretical analysis and self- developed cylindrical Polycrystalline Diamond, the results were as follows. The Ra value observed was as low as 0.08 µm with a tool radius of 1.33mm. All parameters including lubrication were significant in effecting the response parameters [10]. In another study using aluminum and brass of various combinations, the results showed that depth of penetration and burnishing time were the most important parameters controlling the values of both Out of roundness and change in Work-piece diameter. The out of roundness increases with a decrease in initial hardness of work-piece material [11]. In experiments carried out on cylindrical grinding to study the effect of cutting parameters on roundness error and surface roughness, using Taguchi techniques, it was found that surface finish related more towards feed rate and work- speed [12]. In experiments carried out using Polycrystalline diamond the authors have studied the various process parameters influencing burnishing in aluminum. A new

2 2 International Journal of Production and Quality Engineering (IJPQE) phenomenon called Outstripping phenomenon [13] is discussed in certain conditions at high speeds, wherein the surface roughness of burnished surface is lower than that of the tool. In traditional machining, the finished surfaces will have higher surface roughness than that of the tool used. In experiments carried out with respect to magnetic recordings, the use of burnishing process instead of grinding gives better surface finish and requires lesser clearances. The results are better recordings along-with improvement in performance properties. Flying clearances are provided at head disc interface and the resulting distribution provides performance gains with respect to lower magnetic spacing [14]. In another experimental study using design of experiments, burnishing has been successfully applied to hardened materials and the surface roughness is sequentially improved from about 1.83 to ìm on an average on the hardened and tempered (HRC 50) STAVAX plastic mould stainless steel using the ball grinding, ball burnishing and ball polishing [15], similar improvements in surface finish is reported for large dies and moulds using ball burnishing preceded by grinding [16]. In this research paper, an effort is being made to understand the underlying mechanism of improvement in the surface finish of burnished and ground surfaces in a hard material En-8 (also sometimes called as C-45, whose carbon composition is in the range of %). It is commonly used material in making shafts, press-rods and actuator parts in hydraulic and pneumatic industries wherein conventionally cylindrical grinding is done instead of burnishing. Consequently, it is visualized that burnishing gives much better results along with surface work-hardening effect [17], which helps to add surface strength and life to the component. 2. PLAN OF THE EXPERIMENTS One does not have to strive for large experimental data for obtaining reliable and accurate results. A properly planned and executed experiment can provide highly reduced data for collection. Adopting a similar attitude, the fundamental mechanism of the process is being analyzed rather than developing any regression models. In the present study Taguchi L9 orthogonal array has been used for discussing the results of various process parameters. Table 1 shows the process parameters selected for Taguchi s L9 orthogonal array. The processes involved are cylindrical grinding and roller burnishing which were performed on HMT lathe. In order to demonstrate the super finishing in burnishing, this study was initiated taking grinding as a comparison. Table 1 Process Parameters and their Range Process parameters Roller burnishing process Grinding process Levels Spindle speed (rpm) Work feed (mm/rev) Number of passes Lubricant Kerosene Diesel Soluble Oil Kerosene Diesel Soluble Oil Fig. 1: Work-piece and Burnishing Equipment

3 Comparative Study on Surface Finish in Cylindrical Grinding and Roller Burnishing Processes using Taguchi 3 Fig. 2: Sample Showing Turned, Ground and Burnished Surface Fig. 3: En-8 Samples with Rust-preventive Compound The schematic and practical setup for burnishing is shown in Figure 1, while Figures 2 and 3 show the specimens prepared for this study. The specimens were prepared by a HMT NH-26 lathe to represent the conditions for roller burnishing. The work pieces were cut from bar stocks of En-8 material of 25 mm diameter which were initially turned and then ground and burnished adjacently on the same specimen. To measure the surface roughness a standard talysurf was used and average readings were taken from randomly machined surfaces, duly cleaned by acetone. 3. RESULTS OF THE STUDY The results of experiments and S/N data are as plotted in Table 2, and Table 3 shows the average values and main effects of surface roughness in En-8 burnishing at the different levels chosen as per Table 1. Ra values (µm) for roller burnishing process Table 2 Experimental Data and S/N Ratio in Burnishing and Grinding Ra values (µm) for grinding process Test No. Trial I Trial II Trial III S/N ratio Trial I Trial II Trial III S/N ratio Table 3 Average Values and Main Effect in Roller Burnishing Process Level Rotational Feed Rate Number of passes Lubricant parameter speed Types of data Raw S/N Raw S/N Raw S/N Raw S/N Data Data Data Data Data Data Data Data Average values L L L Main effects L 2 -L L 3 -L

4 4 International Journal of Production and Quality Engineering (IJPQE) Fig. 4: Effect of Speed on Surface Roughness (Burnishing) Fig. 5: Effect of Feed on Surface Roughness (Burnishing) Fig. 6: Effect of Passes on Surface Roughness (Burnishing) By performing the ANOVA analysis and plotting the graphs, it is seen that surface roughness decreases with the increase in spindle speed (Figure 4). In conventional material removal processes, this is a commonly observed phenomenon. Besides, surface roughness increases with the increase in feed rate. Figure 5 shows that surface finish is better at lower values of feed rate. At higher values, due to fast rubbing action, the Ra values tend to increase. In Figure 6, it is seen that the surface roughness is minimum at the second pass. At lower and higher values of passes, the surface roughness is found to increase. The reason for this is that the initial profile formed is further compressed by the rollers, which make the surface smooth. This is sometimes again roughened by subsequent tool passes due to pressurized rubbing action of the rollers. From Figure 7, the overall effect of lubricant is negligible, however amongst the lubricants used, kerosene is found to give better results. Table 4 provides the Pooled ANOVA analysis for raw data, and Table 5 corresponds to the pooled ANOVA for S/N results (or signal to noise results). The number of passes has the maximum contribution (34.08%), followed by feed (21.23%) and speed (15.11%). Fig. 7: Effect of Lubrication on Surface Roughness (Burnishing) Table 4 Pooled ANOVA (Raw Data) for Burnishing Process Source SS DOF V F-ratio SS P % Speed (rpm) Feed Number of passes Lubricant Insignificant * * Error Total * Table 5 Pooled ANOVA (S/N Data) for Burnishing Process Source SS DOF V F-ratio SS P % Speed (rpm) Feed Number of passes Lubricant * * Insigni- * * ficant Error Total * Table 6 Depicts the Average Values and Main Effects of Surface Roughness in Grinding.

5 Comparative Study on Surface Finish in Cylindrical Grinding and Roller Burnishing Processes using Taguchi 5 Table 6 Average Values and Main Effects in Grinding Process Level Rotational Feed Rate Number of passes Lubricant parameter speed Types of data Raw S/N Raw S/N Raw S/N Raw S/N Data Data Data Data Data Data Data Data Average values L L L Main effects L 2 -L L 3 -L In the case of En-8 cylindrical grinding, it is experimentally observed that surface roughness value decreases with the increase in spindle speed (Figure 8). As the feed rate increases, surface roughness value decreases (Figure 9). Experimentally, lower feed rates gives better finish in grinding. Nevertheless, for a studied range of this parameter, due to continuous pressurized rubbing, the finish is better for higher values of feed. In the second pass the surface roughness is minimum (Figure 10), whereas at lower passes and higher passes, it is found to increase. The reason could be that with more passes the surface becomes rough since there is some pressure applied, whereas in case of a single pass, the peaks are not fully flattened to get appreciable effect of smoothness. After a pass, the surface irregularities are balanced, and enhanced finish is obtained. Amongst the lubricants, diesel is found to give better results followed by kerosene and soluble oils (Figure 11). Fig. 8: Effect of Speed on Surface Roughness (Grinding) Fig. 9: Effect of Feed on Surface Roughness (Grinding) Fig. 10: Effect of Passes on Surface Roughness (Grinding) Fig. 11: Effect of Lubrication on Surface Roughness (Grinding)

6 ( Ra) 6 International Journal of Production and Quality Engineering (IJPQE) The Table 7 gives the results of ANOVA analysis of raw data, and Table 8 corresponds to ANOVA analysis of S/N data on ground En-8 specimens. According to the ANOVA analysis made for cylindrical grinding, the number of passes present the maximum contribution (50.03%) followed by feed (14.13%) and speed (12.67%), and lubricant has a negligible effect. Table 7 Pooled ANOVA (Raw Data) for Grinding Process Source SS DOF V F-ratio SS P % Speed (rpm) Feed Number of passes Lubricant Insigni- * * ficant Error Total * Table 8 Pooled ANOVA (S/N Data) for Grinding Process Source SS DOF V F-ratio SS P % Speed (rpm) Feed Number of passes Lubricant * * Insigni- * * ficant Error Total * Figure 12 and 13 shows the SEM photographs of burnished and ground surfaces of En-8 specimens. The analysis shows that there is no change in the microstructures of these specimens before and after processing. The surface consists of uniformly dispersed, fine equiaxed grains of pearlite and ferrite. No segregation is seen. The grain size number is 8. The test reference was made through NABL accredited Lab as per IS 7739 (PART V) (RA 1996). Fig. 12: SEM Photographs for Burnishing with 100X and 400X 4. CONCLUSIONS Fig. 13: SEM Photographs for Grinding with 100X and 400X Roller burnishing process for which the results are reported in this paper can be considered as one of the important processes for machining of precision components. Within the range of test conditions employed, the following conclusions can be drawn: 1. It is possible to use burnishing on harder surfaces like En-8 yielding much better surface finish and surface integrity. 2. Roller burnishing produces superior surface finish with absence of feed marks of the burnishing tool. The average surface roughness obtained was 0.21 µm in burnishing, and finest Ra value observed was 0.13 µm (Table 2). 3. On the contrary, cylindrical grinding produces good surface finish with absence of tool feed marks, however the surface roughness values observed are worse. In the results, the average surface roughness value observed is Ra =0.503 µm in grinding, and the finest value is Ra = 0.32 µm (Table 2). 4. Number of passes, feed and spindle speed contribute maximum to the improvements in surface roughness in grinding and burnishing of En-8 specimens. 5. The tool cost of burnishing is comparatively 4 to 5 times higher than grinding, this is however compensated by the inherent advantages in burnishing such as increase in micro-hardness and better surface finish, without necessarily change of the set-up and tooling. REFERENCES [1] A.J. Black, P.L.B. Oxely, Analysis and Experimental Investigation of a Simplified Burnishing Process, International Journal of Mechanical Sciences and Research, 39, 1997, [2] Y.C. Lin, S.W. Wang, H.Y. Lai, The Relationship between Surface Roughness and Burnishing Factor in the Burnishing Process, International Journal of Advanced Manufacturing Technology, 23, 2004,

7 Comparative Study on Surface Finish in Cylindrical Grinding and Roller Burnishing Processes using Taguchi 7 [3] T. Morimoto, K. Tamamura, Burnishing Process using a Rotating Bal-toll-effect of Tool Material on the Burnishing Process, Wear147 (1991) [4] A.M. Hassan, A.M. Maqablesh, The Effects of Initial Burnishing Parameters on Non-ferrous Components, Journal of Materials Processing Technology, 102, 2000, [5] A.M. Hassan, An Investigation into the Surface Characteristics of Burnished Cast Al-Cu Alloys, International Journal of Machining and Manufacturing, 37, 1997, [6] S. Rajesham, Jem Cheong Tak, A Study of the Surface Characteristics of Burnished Components, Journal of Mechanical Working and Technology, 20, 1989, [7] M. Fattouh, M.H. El-Axir, S.M. Serage, Investigations into the Burnishing of External Cylindrical Surfaces of 70/30 Cu-Zn Alloy, Wear, 127, 1988, [8] Y.C. Lin, B.H. Yan, F.Y. Huang, Surface Improvement using a Combination of Electrical Discharge Machining with Ball Burnish Machining based on the Taguchi Method, International Journal of Advanced Manufacturing Technology, 18, 2001, [9] M.M. El-Khabeery, M.H. El-Axir, Experimental Techniques for Studying the Effects of Milling Rollerburnishing Parameters on Surface Integrity, International Journal of Machine Tools and Manufacture, 42, 2001, [10] Hongyun Luo, Jiangying Liu, Lijiyang Wang, Qunpeng Zhong, Investigation of the Burnishing Process using PCD Tool on Non-ferrous Metals, International Journal of Advanced Manufacturing Technology, 25, 2005, [11] M.H. El-Axir, M.M. El-Khabeery, Influence of Orthogonal Burnishing Parameters on Surface Characteristics for Various Materials, Journal of Material Processing Technology, 132, 2003, [12] H. Saglam, F. Unsacar, S. Yaldiz An Experimental Investigation as to the Effect of Cutting Parameters on Roundness Error & Surface Roughness in Cylindrical Grinding, International Journal of Production Research, 43, 2005, [13] Hongyun Luo, Lijiang Wang, Chuang Zhang, Study on Al Alloy Burnishing Process and the Existence of Outstripping Phenomenon, Journal of Material Processing Technology, 116, 2001, [14] B. Strom, S. Deits, C. Gerber, D. Kranjnovich, D. Ohlsen, R. Turner Burnishing Heads in Drive for Higher Density Recording, IEEE Transactions on Magnetics, 40(1), 2004, [15] Fang-Jung Shiou, Chin-Cheng Hsu, Surface Finish of Hard and Tempered Stainless Steel using Sequential Ball Grinding, Ball Burnishing and Ball Polishing Process on Machining Centres, Journal of Materials Processing Technology, 205(1-3), 2008, [16] L.N. López de Lacalle, A. Lamikiz, F.J. Campa, Surface Enhancement of Large Dies and Moulds by Ballburnishing, ASME International Mechanical Engineering Congress and Exhibition, Orlando, USA, November [17] C.S. Jawalkar, R.S. Walia, Experimental Investigations into Micro-hardness in Roller Burnishing Processes on EN-8 and Aluminium Specimens, using Design of Experiments, Proceedings of the 2nd International & 23rd AIMTDR Conference, IIT Chennai, 2008,

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