Design & Fabrication of a Burnishing Tool for Improving Productivity

Submitted To: Prof. Rahul Vaishya Prof. C S Jawalkar Prof. N M Suri

SUBMITTED BY: Ankur Goyal 10109033 Gaurav Jindal 10109041 Ankit Singla 10109032 Ashish Jindal 10109037 Danish Sodhi 09109008

Process of Burnishing
Roller Burnishing is a Cold Working process which produces a fine surface finish by the planetary rotation of hardened rollers over a bored or turned metal surface. Since all machined surfaces consist of a series of peaks and valleys of irregular height and spacing, the plastic deformation created by roller burnishing is a displacement of the material in the peaks which cold flows under pressure into the valleys. The result is a mirrorlike finish with a tough, work hardened, wear and corrosion resistant surface.

Advantages
Mirror Finish in One Pass, Accurate Sizing, Close Tolerances, Eliminates Lapping & Honing Improved Metallurgical Properties - Work Hardened Surface, Increase in fatigue strength, No Additional Machine Investment - attachable to any standard machine present in the shop. Long Tool Life No Operator Skill Required Low Torque & Power Requirements

Table 1.1 shows the various surface finish methods and their surface finish ranges. Process

Average applications

Grinding Lapping Honing Buffing Super finishing

0.1 to 1.6 0.05 to 0.4 0.1 to 0.8 0.05 to 0.5 0.05 to0.2 0.2 to 0.8

Burnishing

Typical Ranges of surface finish, Ra, m

Roller Burnishing improves the finish and size of surfaces of revolution such as cylinders and conical surfaces. Both internal and external surfaces can be burnished using an appropriate tool.

TYPES OF BURNISHING PROCESSES

ROLLER BURNISHER BALL BURNISHER

REQUIREMENTS FOR SUCCESSFUL BURNISHING PROCESS

Ductile material Control work-piece Hardness Suitable surface preparation Proper size control

COST REDUCTION BY BURNISHING PROCESS

Process time Handling (by complete finishing) Short lead time Less capital bound in WIP No waste disposal costs No costs for personnel protection (for noise, dust, fumes) Low energy costs

APPLICATIONS OF ROLLER BURNISHING TOOLS

The burnishing Tools are used for: GM / Bronze Bushes Connecting Rod Small / Big End Rocker Arm Valve Guide Bearing Housing Motor End Cover End Shields Piston G.P. Holes Rotor Stamping I.D. Brake Cylinders Master Cylinders Pneumatic Cylinders Hydraulic Cylinders Valve Rod Mixie Shaft Fan Rotor Shaft Long Holes, Pipes etc

Assembly- Burnishing Tool

STUDY PAPER ON EFFECT OF PARAMETERS ON SURFACE ROUGHNESS AND HARDNESS

Effect of the number of burnishing tool passes on surface roughness of brass specimen by ball burnishing.
S. NO. 1 2 1.24 3 0.76 4 0.51 5 0.62 Surface 1.95 roughne ss Ra m

Initial surface roughness, Rai = 3.96 m.

Effect of burnishing force on surface roughness of brass specimen by roller burnishing.

S. No. 1 2 1.86 3 0.93 4 0.58 5 0.74 Surface 2.87 roughne ss Ra m

Initial surface roughness, Rai = 3.96 m.

Effect of number of burnishing tool passes on surface hardness of brass specimens by ball burnishing.
S. No. Surface hardnes s HRB 1 65 2 70 3 75 4 80 5 85

Initial surface hardness, HRBi= 63

Effect of burnishing force on the surface hardness of brass specimen by roller burnishing.
S. No. Surface hardnes s HRB 1 67 2 71 3 75 4 79 5 83

Initial surface hardness, HRBi= 63

RESULTS AND REASONS

Surface roughness decreases with the increase in number of burnishing tool passes up to a minimum value. After that, the surface roughness increases with the increase in number of burnishing tool passes. REASON is - after a particular number of passes, the surface layer becomes highly work hardened, causing flaking to occur. This will lead to the deterioration of the surface and an increase in the surface roughness.

 Surface hardness on specimens increases with the increase in the number of tool passes for both ball and roller burnishing processes. Also, it is noted from the curves that the increase in surface hardness improvement is more after three passes, for ball burnished specimens. It is observed from the above figure that the force for roller burnishing is greater than that for ball burnishing.

 Increase in surface hardness will level off at high values of number of burnishing tool passes or burnishing force. This is because all metals will have a definite capacity for cold working.

 Surface roughness is lower and surface hardness is greater in Ball burnishing when compared to that in roller burnishing, even when the burnishing force of the ball burnishing is less.

REFERENCES
www.teco.net.au/ppt/ecoroll_burnishing.ppt machiningbymorley.wikispaces.com/file/view/KrarUnit26.ppt? http://www.mechindia.com/BurnishingProcess.html www.ipublishing.co.in/jarvol1no12010/EIJAER2043.pdf? http://me.emu.edu.tr/me364/ME364_abrasive_finishing.pdf http://www.engineershandbook.com/MfgMethods.htm http://www.sunnen.com/NewsDetails.aspx?NewsID=28 http://www.inspire.ethz.ch/iwf/research/processes/concluded_proj ects/undefined_cutting/projektblatt_honen_englisch.pdf http://www.eng.utoledo.edu/pmmc/issue2-3.pdf http://www.brushresearch.com/pdf/GB.pdf http://www.gehring.de/fileadmin/gehring.de/pdf/downloads/Imag e%20Brochure.pdf

THANK YOU