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Application of Diamond Burnishing to Improve the Performance of Materials

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A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Applied Industrial Technologies".

Deadline for manuscript submissions: 15 March 2025 | Viewed by 12200

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Special Issue Editors

Prof. Dr. Jordan Todorov Maximov

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Guest Editor

Material Science and Mechanics of Materials, Technical University of Gabrovo, 5300 Gabrovo, Bulgaria
Interests: mechanics of materials; surface engineering; surface integrity; fatigue strength improvement; wear resistance improvement; surface coldworking
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Galya Velikova Duncheva

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Guest Editor

Material Science and Mechanics of Materials, Technical University of Gabrovo, 5300 Gabrovo, Bulgaria
Interests: mechanics of materials; surface engineering; surface integrity; fatigue strength improvement; wear resistance improvement; surface coldworking; process optimization; finite element simulation
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

It is known that the conditions and service life of components depend, to the greatest extent, on the complex state of the surface layers, i.e., from surface integrity (SI). Therefore, a modern direction in applied engineering sciences these days is surface engineering (SE), which refers to a wide range of techniques and technologies for modifying surface layers in order to improve the operational behavior, aesthetics and economic value of components. For a given material and operating conditions, the component operational behavior depends on the specific SI obtained after applying the relevant finishing process. Therefore, the object of SE is the "SE process - SI - operating behavior" correlation. A cost-effective group of processes within the scope of SE are mechanical surface treatment processes via cold plastic deformation, both dynamic and static, the latter being known as burnishing processes. The most popular static burnishing process, which uses sliding contact between the deforming element and surface being treated, is diamond burnishing (DB). The presence of sliding contact defines the specificity of DB and extends its ability to improve the operating behavior of a wide range of materials. This Special Issue focuses on presenting the latest research on the application of DB to improve the performance of different materials, which find application in various sectors of the industry, such as automotive, machine building, energy, petroleum and chemical industries, biomedicine, etc.

Potential topics include the following:

Correlation between DB process parameters and SI characteristics;
Correlation between the SI characteristics obtained through DB and the operational behavior of the corresponding component (fatigue, wear, corrosion resistance and others);
Development of novel processes for modifying surface layers based on combining DB with other SE processes;
Development and research of novel diamond and other structures as materials for deforming elements in slide burnishing processes;
DB application for processing complex surfaces and novel materials;
Development of novel slide burnishing tools and devices and novel strategies for the processing of slide DB deforming elements and tools;
Exploring the physical nature of slide DB processes:

Wear resistance of the deforming element;
Friction coefficient between the deforming element and the processed material;
Energy exchange in tool–workpiece system.

Development and application of optimization procedures in slide DB process.

Prof. Dr. Jordan Todorov Maximov
Prof. Dr. Galya Velikova Duncheva
Guest Editors

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Keywords

slide burnishing
diamond burnishing
surface integrity
microhardness
surface topography
residual stresses
microstructure
fatigue behaviour
wear resistance
corrosion resistance

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Published Papers (6 papers)

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Research

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14 pages, 4368 KiB

Open AccessArticle

Effect of Slide Diamond Burnishing on the Surface Layer of Valve Stems and the Durability of the Stem-Graphite Seal Friction Pair

by Mieczyslaw Korzynski, Kazimiera Dudek and Katarzyna Korzynska

Appl. Sci. 2023, 13(11), 6392; https://doi.org/10.3390/app13116392 - 23 May 2023

Cited by 11 | Viewed by 1557

Abstract

This study analysed the condition of the surface layer of valve stems made of 317Ti steel after polishing and burnishing. Surface roughness, microhardness, and residual stress tests were carried out. The tests were carried out to determine the effect of the condition of the surface layer (especially non-standard parameters of surface roughness) of the stems on the durability of valves and to determine the possibility of obtaining a favourable state by means of sliding burnishing. Significant differences were observed in the values of the roughness parameters that determine the tribological properties of the surface, and higher surface microhardness and residual compressive stresses were obtained after burnishing. The durability of the stem-graphite seal in a reciprocating movement was tested, and the failure-free operation time of valves with burnished stems was approximately four times longer, which is the premise for recommending sliding diamond burnishing as a finishing treatment for valve stems. Full article

(This article belongs to the Special Issue Application of Diamond Burnishing to Improve the Performance of Materials)

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21 pages, 6813 KiB

Open AccessArticle

Finite Element Simulation and Experimental Investigation of Nanostructuring Burnishing AISI 52100 Steel Using an Inclined Flat Cylindrical Tool

by Victor Kuznetsov, Igor Smolin, Andrey Skorobogatov and Ayan Akhmetov

Appl. Sci. 2023, 13(9), 5324; https://doi.org/10.3390/app13095324 - 24 Apr 2023

Cited by 3 | Viewed by 1638

Abstract

This article is devoted to the development of a sliding burnishing scheme using a flat cylindrical indenter. The previously established patterns of nanostructured state formation in the AISI 52100 steel subsurface layer showed a need to create a special tool with a variable tilt angle of the indenter and with force regulation. A new tool with a cubic boron nitride indenter opens wide possibilities for nanostructuring burnishing of hardened bearing steel. Firstly, a flat cylindrical indenter has high durability due to repeated rotation around its axis. Secondly, the change of the tilt angle to the treated surface allows controlling the contact compression pressure and plastic shear deformation, which determines the formation of a nanostructured state of the material by the method of severe plastic deformation (SPD). The purpose of the work is to determine the optimal parameters of the process and tool in order to form a nanostructure and significantly increase surface layer microhardness. The goal was achieved by the methods of finite element modeling (FEM) and experimental studies of burnishing when the indenter tilt angle changes from 0.5° to 2.5° under dry processing conditions. Numerical simulation of the process made it possible to establish optimal values of the indenter tilt angle of 2° and the burnishing force 250 N according to the criteria of maximum contact pressure and cumulative deformation. The experimental studies of cumulative deformations and the coefficient of friction by the method of burnishing a split disc and dynamometry of the process confirmed the FEM results. The transmission microscopy, durometry, and 3D surface profilometry showed the sensitivity of nanocrystallite sizes, microhardness, and roughness to an indenter tilt angle and confirmed the optimality of the established tilt angle value. Full article

(This article belongs to the Special Issue Application of Diamond Burnishing to Improve the Performance of Materials)

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25 pages, 8892 KiB

Open AccessArticle

Effects of Heat Treatment and Diamond Burnishing on Fatigue Behaviour and Corrosion Resistance of AISI 304 Austenitic Stainless Steel

by Jordan Maximov, Galya Duncheva, Angel Anchev, Vladimir Dunchev, Yaroslav Argirov and Maria Nikolova

Appl. Sci. 2023, 13(4), 2570; https://doi.org/10.3390/app13042570 - 16 Feb 2023

Cited by 11 | Viewed by 2035

Abstract

The surface cold working (SCW) of austenitic stainless steel (SS) causes martensitic transformation in the surface layers, and the percentage fraction of the strain-induced martensite depends on the degree of SCW. Higher content of α′−martensite increases the surface micro-hardness and fatigue strength, but deterioration of the corrosion resistance is possible. Therefore, the desired operational behaviour of austenitic SS can be ensured by the corresponding degree of SCW and heat treatment. This article evaluates the effects of SCW performed by diamond burnishing (DB) and heat treatment on the surface integrity (SI), rotating fatigue strength, and corrosion resistance of AISI 304 austenitic SS for two initial states: as-received hot-rolled bar and initially heat-treated at 1100 °C for one hour followed by quenching in water. Then, DB was implemented as a smoothing and hardening process, both alone and in combination with heat treatment at 350 °C for three hours after DB. The electrochemical performance was examined by open circuit potential measurements, followed by potentiodynamic tests. For both initial states, smoothing DB provided the lowest roughness, whereas an improvement in the maximum surface micro-hardness was obtained after hardening DB and subsequent heat treatment. The maximum fatigue strength was obtained by hardening multi-pass DB without subsequent heat treatment for the as-received initial state. Smoothing DB and subsequent heat treatment maximised the surface corrosion resistance for the two initial states, whereas a minimum corrosion rate was obtained for the initially heat-treated state. For the as-received state, smoothing DB and subsequent heat treatment simultaneously lead to a high fatigue limit (equal to that obtained by hardening single-pass DB) and a low corrosion rate. Full article

(This article belongs to the Special Issue Application of Diamond Burnishing to Improve the Performance of Materials)

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29 pages, 52456 KiB

Open AccessFeature PaperArticle

Using the FEM Method in the Prediction of Stress and Deformation in the Processing Zone of an Elastic/Visco-Plastic Material during Diamond Sliding Burnishing

by Jarosław Chodór, Leon Kukiełka, Grzegorz Chomka, Łukasz Bohdal, Radosław Patyk, Marek Kowalik, Tomasz Trzepieciński and Andrii M. Radchenko

Appl. Sci. 2023, 13(3), 1963; https://doi.org/10.3390/app13031963 - 2 Feb 2023

Cited by 5 | Viewed by 2560

Abstract

This article concerns the application of the FEM method for the prediction of stress and deformation states in the workpiece during diamond sliding burnishing (DSB). An updated Lagrange (UL) description was used to describe the phenomena at a typical incremental step. The states of strain and strain rate are described by non-linear relationships without linearization. The material parameters were estimated during tensile tests to determine the characteristics of the 41Cr4 steel. Its hardness was also tested. Its aim was to prepare a table with the material properties of the above-mentioned steel and its implementation for numerical analyses. A Cowper–Symonds material model was used to model the displacement process of the wedge on an elastic/visco-plastic body reflecting the DSB process. The computer model was validated, and a good convergence of the results was obtained. Applications in the ANSYS/LS-Dyna program were developed to simulate the process of DSB. The results of numerical analyses were presented, among others, to explain the influence of the rake angle on the condition of the surface after machining, as well as the phenomenon of chip formation. The results of numerical simulations were verified experimentally on a test stand. Full article

(This article belongs to the Special Issue Application of Diamond Burnishing to Improve the Performance of Materials)

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19 pages, 4740 KiB

Open AccessFeature PaperArticle

Effect of Diamond Burnishing on the Properties of FSW Joints of EN AW-2024 Aluminum Alloys

by Rafał Kluz, Magdalena Bucior, Andrzej Dzierwa, Katarzyna Antosz, Wojciech Bochnowski and Kamil Ochał

Appl. Sci. 2023, 13(3), 1305; https://doi.org/10.3390/app13031305 - 18 Jan 2023

Cited by 7 | Viewed by 1453

Abstract

The article presents the results of an analysis of the surface roughness parameters, microhardness, and the stresses of the surface layer ofFSW butt joints subjected to the burnishing process with a diamond tip. This can be useful in selecting the optimal parameters of the burnishing process, ensuring the best properties of the surface layer of the FSW joint. Burnishing force and feed rate influence were analyzed according to the two-factor three-level full factorial statistical completed plan PS/DC 3². The tested material was 2024-T3 aluminum alloy sheets with a thickness of 2 mm. The results show that burnishing significantly reduced the surface roughness from Sa = 6.46 μm to Sa in the range of 0.33 μm–1.7 μm. This treatment provides high compressive residual stresses

σ_{x}

from −86 to −130 MPa and

σ_{y}

from −158 to −242 MPa. Microhardness increased from 84.19% to 174.53% compared to butt joints. Based on the obtained results, multi-criteria optimization was carried out. This optimization allows us to obtain a compromise solution ensuring compressive stresses in the surface layer (

σ_{x} = - 123 MPa

and

σ_{y} = - 202 MPa

) and microhardness

H_{V} = 362.56 mm / {mm}^{2}

with the roughness of the weld surface Sa = 0.28 µm, Sku = 3.93 and Spc = 35.88 1/mm. Full article

(This article belongs to the Special Issue Application of Diamond Burnishing to Improve the Performance of Materials)

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Review

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20 pages, 9260 KiB

Open AccessReview

The Correlation between Surface Integrity and Operating Behaviour of Slide Burnished Components—A Review and Prospects

by Jordan Maximov and Galya Duncheva

Appl. Sci. 2023, 13(5), 3313; https://doi.org/10.3390/app13053313 - 5 Mar 2023

Cited by 6 | Viewed by 1525

Abstract

This review paper analyses and summarises the results found while studying the slide burnishing (SB) of metal components refracted through a prism during the surface engineering (SE) process, over the period of January 2019 to January 2023. According to the classification of SE processes defined in the article, SB as a technique in the scope of SE that belongs to the group of static surface cold working (SCW) processes, based on severe surface plastic deformation, and is realised under the condition of sliding friction contact with the treated surface. When the deforming element is natural or artificial diamond, SB is known as diamond burnishing (DB). SB is especially suited for axes, shafts, and holes with circular cross-sections but can also be implemented on flat-face and complex surfaces. SB is eco-friendly and a very economical method for producing mirror-like surface finishes on a wide range of ferrous and non-ferrous machined surfaces, but it can also be realised as a hardening and mixed process with the aim of significantly increasing the fatigue strength and wear resistance of the treated components. Based on a literature review of the results of the theory and practice of SB, an analysis on different criteria was carried out, and graphic visualizations of the statistical results were made. Additionally, the results were analysed using the integrated approach of SE to study the correlations between the apexes of the triangle: SB—surface integrity (SI)—operational behaviour (OB). On this basis, relevant conclusions were drawn, and promising directions for future investigations of SB were outlined. Full article

(This article belongs to the Special Issue Application of Diamond Burnishing to Improve the Performance of Materials)

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