Hard roller burnishing is a cost-effective finishing and surface enhancement process where a ceramic ball rolls on the machined surface to flatten the roughness peaks. The ball is supported and lubricated by hydrostatic fluid in a special tool holder. The process not only improves surface finish but also imposes favorable compressive residual stresses in functional surfaces, which can lead to long fatigue life. Most research in the past focused on experimental studies. There is still a special need for a reliable finite element method (FEM) model that provides a fundamental understanding of the process mechanics. In this study, two-dimensional (2D) and three-dimensional FEM models for hard roller burnishing were established. The developed 2D FEM model was used to study the effects of process parameters (i.e., burnishing pressure, feed rate) on surface finish and residual stresses. The simulation results were evaluated and compared to the experimental data. Results show that the established FEM model could predict the residual stresses and provided useful information for the effect of process parameters. Both FEM and experiments show that burnishing pressure is the most influence, where high burnishing pressure produces less roughness and more compressive residual stress at the surface.
Skip Nav Destination
e-mail: Altan.1@osu.edu
Article navigation
August 2007
Technical Papers
Finite Element Modeling of Hard Roller Burnishing: An Analysis on the Effects of Process Parameters Upon Surface Finish and Residual Stresses
Partchapol Sartkulvanich,
Partchapol Sartkulvanich
Engineering Research Center for Net Shape Manufacturing,
The Ohio State University
, Columbus, OH 43210
Search for other works by this author on:
Taylan Altan,
Taylan Altan
Engineering Research Center for Net Shape Manufacturing,
e-mail: Altan.1@osu.edu
The Ohio State University
, Columbus, OH 43210
Search for other works by this author on:
Francisco Jasso,
Francisco Jasso
Center for Innovation in Design and Technology,
Instituto Tecnológico y de Estudios Superiores de Monterrey
, Monterrey, N.L., Mexico
Search for other works by this author on:
Ciro Rodriguez
Ciro Rodriguez
Center for Innovation in Design and Technology,
Instituto Tecnológico y de Estudios Superiores de Monterrey
, Monterrey, N.L., Mexico
Search for other works by this author on:
Partchapol Sartkulvanich
Engineering Research Center for Net Shape Manufacturing,
The Ohio State University
, Columbus, OH 43210
Taylan Altan
Engineering Research Center for Net Shape Manufacturing,
The Ohio State University
, Columbus, OH 43210e-mail: Altan.1@osu.edu
Francisco Jasso
Center for Innovation in Design and Technology,
Instituto Tecnológico y de Estudios Superiores de Monterrey
, Monterrey, N.L., Mexico
Ciro Rodriguez
Center for Innovation in Design and Technology,
Instituto Tecnológico y de Estudios Superiores de Monterrey
, Monterrey, N.L., MexicoJ. Manuf. Sci. Eng. Aug 2007, 129(4): 705-716 (12 pages)
Published Online: February 16, 2007
Article history
Received:
July 19, 2006
Revised:
February 16, 2007
Citation
Sartkulvanich, P., Altan, T., Jasso, F., and Rodriguez, C. (February 16, 2007). "Finite Element Modeling of Hard Roller Burnishing: An Analysis on the Effects of Process Parameters Upon Surface Finish and Residual Stresses." ASME. J. Manuf. Sci. Eng. August 2007; 129(4): 705–716. https://doi.org/10.1115/1.2738121
Download citation file:
Get Email Alerts
Special Issue on the State-of-the-Art in Japanese Manufacturing Research
J. Manuf. Sci. Eng
A Review of Advanced Roll-to-Roll Manufacturing: System Modeling and Control
J. Manuf. Sci. Eng (April 2025)
Related Articles
A Multi-Scale System Analysis and Verification for Improved Contact Fatigue Life Cycle of a Cam-Roller System
J. Tribol (April,2007)
Three-Dimensional Semiperiodic Line Contact–Periodic in Contact Length Direction
J. Tribol (April,2009)
Prediction of Steady State Adhesive Wear in Spur Gears Using the EHL Load Sharing Concept
J. Tribol (April,2009)
Fatigue Life and Traction Modeling of Continuously Variable Transmissions
J. Tribol (October,2002)
Related Proceedings Papers
Related Chapters
Study on Loading Roller Number and Maximum Stress of Roller Bearing used in Rolling Mill Based on FEA
International Conference on Mechanical and Electrical Technology, 3rd, (ICMET-China 2011), Volumes 1–3
Fatigue Performance of Bearing Rollers Manufactured by Laser Powder Bed Fusion
Bearing and Transmission Steels Technology
GA Based Multi Objective Optimization of the Predicted Models of Cutting Temperature, Chip Reduction Co-Efficient and Surface Roughness in Turning AISI 4320 Steel by Uncoated Carbide Insert under HPC Condition
Proceedings of the 2010 International Conference on Mechanical, Industrial, and Manufacturing Technologies (MIMT 2010)