Numerical Investigation of Ball Burnishing Process Using a Comprehensive Three-Dimensional Finite Element Model

Abstract In recent decades, the finiteelement method (FEM) has been increasingly recognized as an integral computational tool for the analysis and simulation of manufacturing processes, such as the ball burnishing operation. The current investigation employs FEM to conduct a numerical analysis on the influence of various burnishing parameters–namely, burnishing speed, feed rate, and penetration depth–on the residual stress and strain energy in workpieces processed with three different types of ball burnishing tools: rigid, spring-loaded, and pneumatic. A sophisticated three-dimensional ANSYS finite element model was meticulously crafted to emulate the ball burnishing process. This model allowed for the precise control and variation of input parameters and facilitated a detailed examination of their impact on the predicted residual stress and strain energy in the workpieces. The computational outcomes reveal a direct relationship between the burnishing speed and the induced residual stress and strain energy, with both metrics escalating to a maximum at a specific burnishing speed before exhibiting a subsequent decline. Notably, the model Computes that, at a penetration depth of 0.4 mm, the residual stress and strain energy attain a maximum of 2330 MPa and 107.6 mJ, respectively. Furthermore, the simulation delineates a dependency of the residual stress and strain energy behavior on the type of ball burnishing tool deployed. For instance, the rigid tool is characterized by a consistent escalation in stress and energy up to a speed of 500 revolutions per minute (RPM). Conversely, the spring tool demonstrates a more confined spectrum of stress and energy, peaking at 600 RPM with a feed rate of 0.08 mm/revolution and a penetration depth of 0.4 mm. Meanwhile, the pneumatic tool’s simulation results suggest an insensitivity of the residual stress and strain energy to changes in penetration depth. These exclusively numerical results shed light on the intricate relationship between the burnishing parameters and the consequent simulated mechanical attributes of the workpiece. Additionally, the computational data highlight the disparities in the performance of different ball burnishing tools as anticipated by the finite element analysis. This information provides a theoretical basis for refining the ball burnishing process and customizing surface characteristics to conform to diverse industrial applications as per the predictions of the simulation model. Prospective research endeavors will focus on experimental validation of the simulation results to ascertain the fidelity and practical relevance of the developed model.