Collaborative Research: Finite Element Modeling of Ball Burnishing and Selection of Process Parameters

本研究的研究目标是：(1)建立可靠的球面抛光有限元工艺模型，这是一种机械表面精加工工艺，通常用于提高高应力机械加工零件的表面质量和疲劳寿命；(2)利用该模型来了解工艺机理并分析(硬)车削所产生的初始表面层性能的影响；(3)利用所提出的模型进行工艺优化。所采用的方法包括：(1)确定加工表面层的材料性能作为工艺模型的输入；(2)开发有限元仿真模型(二维和三维)并使用该模型分析工艺参数的影响；(3)进行球磨实验以验证/改进模型预测；以及(4)利用所开发的模型演示典型的硬抛光部件的工艺优化并在生产条件下验证结果。这项工作将包括俄亥俄州立大学、德国亚琛工业大学和托莱多大学以及三个感兴趣的工业合作伙伴Hardinger、Science Fording Corporation和EcoRoll之间的合作，这些合作伙伴将为研究提供免费的软件、硬件和建议。硬车削和球磨相结合的工艺为磨削和研磨操作提供了一种很好的替代方案，并有助于提高结构部件的疲劳寿命。研究结果将为各行业优化抛光工艺、提高表面质量提供有效的分析工具。此外，该项目的成果将有助于降低成本，提高机械加工行业的竞争力。通过与学术界和产业界的共同努力，成果将方便地转移到科学界并应用于生产。这项研究还将向工业界和大学示范如何有效地使用基于有限元方法的过程建模来优化工艺条件，提高制造操作的有效性。

The research objectives of this study are to (1) develop a reliable finite element process model for ball burnishing, which is a mechanical surface-finishing process that is often used to improve the surface quality and fatigue life of highly stressed machined components, (2) use this model to understand the process mechanics and analyze the effects of the initial surface layer properties generated by (hard) turning, and (3) demonstrate process optimization using the proposed model. The approach to be employed includes (1) determining material properties of the machined surface layer as input to the process model, (2) developing a finite element simulation model (in 2 and 3 Dimensions) and using the model to analyze the effect of process parameters, (3) conducting ball burnishing experiments to verify/refine the model predictions, and 4) demonstrating the process optimization of a representative hard burnished component using the developed model and validate the results in production conditions. This work will comprise a collaboration between Ohio State University, the Technical University of Aachen, Germany, and the University of Toledo, and three interested industrial partners, Hardinge, Scientific Forming Corporation, and Ecoroll, that will provide free software, hardware, and suggestions to the study.The process combination of hard turning and ball burnishing provides a good alternative to grinding and honing operations and helps to improve the fatigue life of structured components. The results obtained from this research will provide an efficient analysis tool for many industries to optimize the burnishing operation and to improve the surface quality. In addition, the results of this project will contribute to cost reduction and increased competitiveness in machining industry. Through the collaborative effort with the academic and industrial partners, the results will be conveniently transferred to the scientific community and applied in production. This study will also demonstrate to industry and universities, as an example, how Finite Element Method-based process modeling can be used efficiently to optimize process conditions and enhance the effectiveness of manufacturing operations.