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Effect of working parameters on the surface integrity in cryogenic diamond burnishing of 17-4 PH stainless steel with a novel diamond burnishing tool
Journal of Manufacturing Processes 38 (2019) 564–571
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Effect of working parameters on the surface integrity in cryogenic diamond burnishing of 17-4 PH stainless steel with a novel diamond burnishing tool
T
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Sachin Ba, , Narendranath Sa, D. Chakradharb a b
Department of Mechanical Engineering, National Institute of Technology Karnataka, Surathkal, India Department of Mechanical Engineering, Indian Institute of Technology Palakkad, Kerala, India
A R T I C LE I N FO
A B S T R A C T
Keywords: Cryogenic diamond burnishing MQL Dry Surface integrity 17-4 PH stainless steel
The productivity of the components is adversely affected by the poor surface integrity characteristics as a consequence of the generation of high temperature in the burnishing zone. The abundant use of conventional lubricants causes environmental pollution and health problems. To overcome these issues, cryogenic cooling has been used across the world to reduce the temperature generated in the burnishing zone. It is well known that most of the accidents which involve aero engines have revealed that the reason for this may be due to the failure of the first stage of compressor blades. Hence aerospace material, 17-4 precipitation hardenable (PH) stainless steel can be used in aero engines to minimize the failure occurring due to foreign object damage. In the present study, the effect of cryogenic diamond burnishing on the surface integrity characteristics such as surface roughness, surface hardness, surface morphology, surface topography, subsurface microhardness, and residual stress of 17-4 pH stainless steel have been investigated with a novel diamond burnishing tool and also it has been related to dry and minimum quantity lubrication (MQL) environments. From the experimental results of diamond burnishing process, surface roughness was observed to be reduced by 33%–50%, 34%–51% and 25%–40% in the cryogenic cooling environment in contrast with MQL and dry environments. Similarly, the surface hardness improvement in a cryogenic cooling environment was found to be 5%–7%, 6%–10%, and 6%–9%, in comparison with MQL and dry environments respectively.
1. Introduction A high-quality finishing of the mechanical parts is necessary to obtain the improved fatigue resistance and to attain a low friction ratio. Hence the finishing processes are turned out to be a major drive for industrial innovation all over the globe [1]. Diamond burnishing is one of the chipless finishing processes where the spherical tip of the tool made up of natural diamond, slides on the surface of the workpiece which causes plastic deformation. Directly after turning, the workpiece can be diamond burnished to obtain improved surface integrity properties. It is an economical and compatible process which can be applied on ferrous and nonferrous materials to obtain mirror-like surface finish. It has a higher level of efficiency when compared to grinding, lapping and polishing processes. The pH stainless steel is one of the interesting family of steels which can attain hardness up to 49 HRC [2]. One of the attractive features of 17-4 pH stainless steel is that it provides a great combination of high strength, ease of heat treatment, and excellent corrosion resistance which is not possible to find in any of the steel grades [3,4]. Hence, it
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could be a better choice to be used for the first set of aerospace compressor blades to avoid the problems arising due to the foreign object damage. It has a wide range of applications in the field of aircraft, chemical, petrochemical, food, metal and papermaking industries [5]. It develops more adhesion wear on the tool, and hence it can be categorized under difficult to cut materials [6]. The potential of slide burnishing was presented by Maximov et al. [7] in improving the residual stress, microhardness, and surface finish of high‑strength aluminum alloys. Korhonen et al. [8] observed an improvement in the surface hardness and surface finish while burnishing of Nitronic-50 HS using a diamond coated tip. Korzynski and Zarski [9] clarified the effect of the surface stereometric structure of AZ91 alloy by slide diamond burnishing. Chomienne et al. [10] studied the influence of ball-burnishing on residual stress profile of a 15-5 PH martensitic stainless steel. It was observed that a deep compressive layer would be formed after performing ball burnishing and burnishing force was found to be the most significant parameter. Okada et al. [11] proposed a novel method of a spherical 5 ° of freedom hybrid type mechanism. It was shown that it is possible to minimize the surface
Corresponding author. E-mail address: [email protected] (S. B).
https://doi.org/10.1016/j.jmapro.2019.01.051 Received 24 August 2018; Received in revised form 20 January 2019; Accepted 30 January 2019 1526-6125/ © 2019 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
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Fig. 1. Microstructure and EDS analysis of as received 17-4 PH stainless steel.
roughness of the flat and curved surfaces of the cuboid work material. Kuznetsov et al. [12] performed a study on strain accumulated in the subsurface of HRC5520Cr4 steel samples using nanostructuring burnishing. The influence of the parameters such as friction force and loading repetition was investigated. The experimental results verified the influence of both integral parameters on the performance of the steel sample. Maximov et al. [13] successfully applied slide burnishing on chromium-nickel steels to improve the surface integrity properties such as surface finish, residual stress, microhardness, wear resistance and fatigue strength. Jerez-Mesa et al. [14] investigated the influence of vibration-assisted ball burnishing on the topology of the AISI 1038 specimen. The bearing capacity has been observed to be improved, and its performance was compared with the conventional ball burnishing process. Toboła and Kania [15] investigated the effect of slide burnishing and nitriding phase on the composition and stress state of Sverker 21 and Vanadis 6 steel. The thickness of the effected region was increased in the slide burnished sample when compared to nitriding. The wear resistance of the sample was increased by the sequential turning-slide burnishing-nitriding process. Akkurt [16] compared the performance of drilling, turning, reaming, grinding, honing, and roller burnishing methods in surface finishing of AISI 304 austenitic stainless steel drilled holes. It was concluded that roller burnishing was successful in producing a superior quality of the drilled hole. Korzynski et al. [17] revealed that the slide diamond burnishing is one of the best methods to obtain the equilibrium surface texture of the valve stems. John et al. [18] carried out roller burnishing on EN-9 grade alloy steel and achieved a reduction in the surface roughness by 94.5% and improvement in the surface hardness by 41.7%. Sova et al. [19] conducted a study on the effect of sequential turning and burnishing on the residual stress and microstructure of 17-4 pH stainless steel cold spray deposits. It was revealed that turning was able to induce tensile residual stress and ball burnishing was successful in inducing compressive residual stress. Millions of workers get affected by working under different kinds of cutting fluids. Aerosol particles or mist are some of the hazardous elements which will be generated during the application of different types of cutting fluids during machining and which effects most of the human organs. Cryogenic has emerged as an alternative cutting fluid in the last two decades. Usually, liquid nitrogen (LN2) will be sprayed at the interface of the tool and workpiece. It is environmental friendly coolant when compared to other conventional coolants. During the burnishing process because of the pressure created in the burnishing zone, the temperature at that region increases. By the application of LN2, the temperature generated can be reduced which results in improved surface integrity properties of the material. Pu et al. [20] investigated the influence of cryogenic burnishing on AZ31B Mg alloy and confirmed an enhancement in corrosion resistance and surface hardness of the material. Tang et al. [21] clarified the corrosion resistance improvement along with the formation of uniform grains after cryogenic burnishing on titanium alloy. It was also claimed that surface roughness was minimized because of the effect of LN2. Huang et al. [22] proved that refined nano grains were formed during cryogenic burnishing on Al 7050-T7451 alloy. The hardness of the material was increased in a
cryogenic environment when compared to a dry environment. Pu et al. [23] reported the formation of ultrafine grain structure on Mg-Al-Zn alloy after performing cryogenic burnishing and also improved corrosion resistance was achieved. Yang et al. [24] explored the effect of cryogenic burnishing on Co-Cr-Mo biomaterial and attained improved surface integrity properties after cryogenic burnishing. 17-4 pH stainless steel finds applications in abundant key fields, so it is very much essential to perform a broad study on the diverse machinability perspectives. From the previous studies, it has been observed that inadequate literature is available on surface integrity investigation of diamond burnishing process under cryogenic, MQL and dry environments. There are not many evidence present in the literature regarding the potential of diamond burnishing in improving the quality of the surface of 17-4 PH stainless steel. Hence there is a necessity to understand the effect of control factors on diamond burnishing of 17-4 pH stainless steel under cryogenic, MQL and dry environments. To the author’s knowledge, not many kinds of literature are available on diamond burnishing process with the proposed novel diamond burnishing tool. Hence, the main objective of the current investigation is to study the influence of novel diamond burnishing tool on surface integrity properties of 17-4 PH stainless steel under cryogenic, MQL and dry environments. 2. Materials and method 2.1. Material selection The material under consideration for the present research work is 17-4 pH stainless steel procured in the form of a cylindrical bar of 32 mm diameter and 150 mm length. The chemical composition of the material is Ni - 4.62%; Cr - 18.53%; Cu - 2.96%; Si - 0.07%; C - 6.03%; P - 0.51% and Fe-Balance. The microstructure and the energy dispersive x-ray spectroscopy (EDS) analysis of as received material is as depicted in Fig. 1. The surface roughness after burnishing purely depends on the surface roughness before burnishing [25,26]. Hence the top layer of the cylindrical rod has been removed, and its size has been reduced to 30 mm diameter. AlTiN PVD coated KC5010 tungsten coated carbide insert was used for turning operation with a constant cutting velocity of 73 m/min, feed rate of 0.1 mm/rev, and depth of 0.25 mm. The average surface roughness and surface hardness before diamond burnishing were found to be 1.20 μm and 340 HV respectively. Based on the preliminary investigation and literature review the diamond burnishing process parameters have been selected. The process parameters and their levels are given in Table 1. 2.2. Experimental details The experiments have been carried out by ‘one-factor-at-the-time’ approach. ‘Kirloskar’ conventional lathe has been used in the present investigation to perform diamond burnishing. The surface roughness was measured by using ‘MITUTOYO’ make Talysurf ‘SJ3010′ model. Vickers hardness tester model ‘VM-120′ was used to measure the surface hardness. An average of three readings was recorded for both 565
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Table 1 Process parameters and their levels. Burnishing process parameters
Burnishing speed (S) Burnishing feed (f) Burnishing force (F)
Unit
m/min mm/rev N
Levels 1
2
3
4
5
21 0.048 50
30 0.055 88
47 0.065 125
73 0.079 163
113 0.096 200
Fig. 3. A novel diamond burnishing tool.
surface roughness and surface hardness. Three number of samples were tested under the same condition for one environment and for each sample the experimentation was carried out three times. Diamond burnished surface morphology was studied by ‘JEOL-JSM-638OLA’ model scanning electron microscope (SEM). The surface topography of the burnished surface has been obtained by ‘LESTOLS4100′ model confocal laser 3D surface tester. Residual stress has been measured by X-ray diffraction with MGR40 P stress measurement system make ‘PROTO.’ Microstructure and elemental composition of burnished samples have been measured by ‘Zeiss’ Scanning electron microscope, and ‘Oxford’ make ‘X-ACT’ type EDS. Vickers microhardness tester type ‘OMNI TECHMVHS-AUTO’ was used to measure the subsurface microhardness after diamond burnishing. Before measuring the microhardness of the specimen, it was subjected to cold mounting by acrylic powder and self-curing liquid. These samples were polished to obtain the exact indentation mark on the specimen. The diamond burnished samples were polished by emery papers of different grades and diamond paste to obtain the mirror finished surface. The present investigation has been carried out under three diamond burnishing modes namely cryogenic, MQL and dry environments. The flow rate of LN2 supplied in the burnishing zone was 0.45 kg/min. The schematic of cryogenic diamond burnishing set up is depicted in Fig. 2. Cryocan of ‘TA55′ model has been used for storing the LN2. The LN2 is maintained at a temperature of -196 °C inside the tank. LN2 was pressurized by applying suitable required pressure to the tank by the air compressor. It is supplied through the nozzle of 1 mm diameter at a pressure of 3 bar, and it is directed towards the tool-workpiece interface. ‘DAOML - 2/ PS / FS/’MQL set up has been used for the present research work. The oil mist was supplied through the external nozzle at a flow rate of 70 ml/h.
diamond burnishing tool for carrying out the diamond burnishing experiments. The tool contains two parts. The first one is the diamond stem and the second part is a shank. The stem of the tool contains a spherical diamond tip. The modification has been done in such a way that the stem of the tool can be removed easily from the shank by using button head screw without removing the tool from the fixed position. The movement of the stem will compress the spring which can be used to measure the applied burnishing force. In the novel diamond burnishing tool, heavy duty springs have been used with an increased number of coils whereas in conventional tool light duty springs have been used. These springs are capable of absorbing any possible vibration induced by the machine bed and also in minimizing the positioning error of the diamond burnishing tool. To transmit the burnishing force to the tool and also for the easy movement of the spring inside the tool, spring guide has been used. The square shank of the conventional tool has larger overhang while the newly modified tool has a better reach with smaller overhang. Attachment to the conventional lathe or CNC machine has become easy because of the extra grip provided with a newly designed tool. Dowel pin has been attached to the tool for the measurement of the deflection of the spring, and it was not present in the conventional tool where the measurement of burnishing force was difficult in contrast with the novel diamond burnishing tool. When the burnishing force is applied to the tool, the deflection readings of the spring was measured by a dial gauge. Whereas in the conventional tool the measurement of the deflection was difficult due to the absence of a dowel pin. In the preliminary experimentation and from the literature, it was perceived that a spherical diamond tip of the moderate radius would help to improve surface hardness and surface finish of the material. Hence in the present research work, a spherical diamond tip of radius 3.5 mm was used. The length of the stem of the tool has been reduced to avoid more stress acting on the tool while applying burnishing force.
2.3. Novel diamond burnishing tool 3. Results and discussion
To fulfill the requirements of the diamond burnishing process and to overcome the drawbacks faced by the manufacturers while using a conventional tool, a novel diamond burnishing tool has been used in the present investigation. Fig. 3 shows the specially designed and fabricated
In the present study, the performance of a novel diamond burnishing tool on surface integrity properties of 17-4 PH stainless steel was investigated. The surface integrity properties which have been considered for further study are surface roughness, surface hardness, surface morphology, surface topography, subsurface microhardness, and residual stress. 3.1. Analysis of surface roughness 3.1.1. Effect of burnishing speed and cryogenic cooling on surface roughness Performance of the mechanical components purely depends on the quality of the burnished surface of the material. From Fig. 4(a), it is noted that the surface roughness decreases from a burnishing speed of 21 m/min to 47 m/min and further increase in the burnishing speed from 47 m/min to 113 m/min leads to an increase in the surface roughness. The reason being, at lower burnishing speed the temperature generated in the burnishing zone will be reduced due to the constant spraying of LN2 and as the burnishing speed increases the temperature increases which results in possible chattering and is the reason for an increase in the surface roughness [27]. In MQL environment oil
Fig. 2. Schematic of cryogenic diamond burnishing. 566
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Fig. 4. Variation of surface roughness at varying (a) burnishing speed (b) burnishing feed and (c) burnishing force in the cryogenic, MQL and dry environments.
3.1.3. Effect of burnishing force and cryogenic cooling on surface roughness As indicated in Fig. 4(c), the surface roughness decreases at a lower range of burnishing force and a further increase in the burnishing force from 125 N to 200 N leads to an increase in the surface roughness. The reason for this variation in the surface roughness may be because of the incomplete plastic deformation of the asperities, which leads to decreased surface roughness at the lower burnishing force. The repeated plastic deformation on the surface of the workpiece results in increased work hardening at a higher range of burnishing force which causes flaking on the surface, and hence the surface finish deteriorates [29,30]. The surface roughness in the cryogenic environment is minimum when compared to all other environments because spraying of LN2 in the burnishing zone prevents the chemical and mechanical degradation of the burnished surface. Minimum surface roughness recorded was 0.03 μm in the cryogenic environment. It was found that the surface roughness was reduced by 25% and 40% in the cryogenic environment in contrast with MQL and dry environments respectively.
mist is sprayed at the workpiece-tool interface which reduces the temperature in the burnishing zone. In a dry environment because of the absence of lubrication the surface roughness recorded was higher than the other two environments. Another reason to be noted is that the material transformation takes place between the tool and the workpiece which results in maximizing the surface roughness at higher burnishing speed [28]. All the surface roughness measurements were carried out at a constant burnishing feed of 0.065 mm/rev and burnishing force of 125 N. The variation of burnishing speed was between 21 m/min to 113 m/min. In all the three environments similar trend has been observed for surface roughness. The lowest surface roughness was recorded for a burnishing speed of 47 m/min. An improvement of 33% was observed in the cryogenic environment in contrast with MQL environment. Similarly, 50% improvement was observed when compared to the dry environment.
3.1.2. Effect of burnishing feed and cryogenic cooling on surface roughness Fig. 4(b) indicates that the surface roughness decreases with an increase in the burnishing feed up to 0.055 mm/rev. The reason for this decrease could be elucidated by the fact that at a lower level of burnishing feed, the consecutive traces of the diamond tip on the surface of the workpiece will be small since the tool moves slowly over the workpiece [29]. As there is an increase in the burnishing feed from 0.055 mm/rev, a sudden increase in the surface roughness has been observed. The reason being, at upper limits of burnishing feed, the space between consecutive traces of the diamond tip increases. Another reason may be due to the minimum time available to the diamond tip to clear the bulged edges of the former traces [29]. The feed marks have been generated at the higher burnishing feed which can be seen from Fig. 5(b) and (c). The variation in the cryogenic environment is observed due to the splashing of the LN2 in the burnishing zone leads to lower coefficient of friction and also minimum vibration has been observed which leads to minimum feed marks on the burnished specimen. In all the three environments similar trend has been observed. The cryogenic environment has produced lowest surface roughness when compared to MQL and dry environments. The percentage of reduction was found to be 34% and 51% in contrast with MQL and dry environments respectively.
3.2. Analysis of surface morphology The diamond burnished surface morphology has been shown in Fig. 5(a), (b) and (c). The SEM images were obtained at the burnishing speed of 47 m/min, burnishing feed of 0.065 mm/rev and burnishing force of 125 N. The SEM images of the diamond burnished surface clearly show that uniform surface has been formed after diamond burnishing in the cryogenic environment. The cryogenic diamond burnished surface has the most regular surface in comparison with the MQL and dry environment which has been shown in Fig. 5(a). Uniform surface was observed in the cryogenic environment because of the presence of the cooling effect of LN2 at the interface of the tool and the workpiece. It results in the easy flow of the material and because of which the voids have been filled. The effect of feed marks was reduced in the case of cryogenic diamond burnishing due to the cooling effect of the LN2 in the burnished zone. In the previous discussion about the surface roughness, it was noticed that the surface roughness achieved for the cryogenic environment was minimum in contrast with MQL and dry environments. Similar observations have been made in Fig. 5(a). It was found that the feed marks have been generated and a similar effect has been observed in the SEM images of MQL environment which can be seen from Fig. 5(b). Micro voids have been observed in MQL 567
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Fig. 5. Surface morphology of the diamond burnished surface observed at burnishing speed of 47 m/min, burnishing feed of 0.065 mm/rev and burnishing force of 125 N in (a) Cryogenic (b) MQL and (c) Dry environments.
environments have shown increased peak to valley height because of the presence of higher temperature in the burnishing zone. From the results of SEM images and surface topography, it is pragmatic that cryogenic diamond burnishing yields improved surface finish which helps to improve the performance of the product in contrast with other working environments.
environment because of the improper deposition of the material in the voids and also an easy flow of the metal has been suppressed in MQL environment in contrast with the cryogenic environment. The splashing of the oil mist in the burnishing zone reduces the heat generated, and henceforth the surface roughness has been minimized in comparison with the dry environment. However, because of the absence of lubrication in a dry environment, the presence of feed marks and voids were visible as shown in Fig. 5(c). Micro cracks have been observed in the dry environment because of the excess heat produced in the burnishing zone due to the absence of lubrication.
3.4. Analysis of surface hardness 3.4.1. Effect of burnishing speed and cryogenic cooling on surface hardness The surface hardness variation concerning varying burnishing speed reveals that the surface hardness of the material decreases continuously when there is an increase in the burnishing speed. The temperature at the tool and workpiece interface increases as the burnishing speed increases, and also at higher burnishing speed, the chattering has been induced due to which the surface hardness decreases [31]. At a constant burnishing feed of 0.065 mm/rev and burnishing force of 125 N, the above trend has been achieved. The variation of the surface hardness with burnishing speed is represented in Fig. 7(a). The surface hardness improvement of 5% and 7% was observed in the cryogenic environment when compared to MQL and dry environment at a burnishing speed of 21 m/min. An absolute improvement in the surface hardness in the cryogenic environment was observed due to the constant spraying of LN2 in the burnishing zone which reduces the temperature accumulated
3.3. Analysis of surface topography The 3D surface topography has been measured at the burnishing speed of 47 m/min, burnishing feed of 0.065 mm/rev and burnishing force of 125 N under all the three environments which are represented in Fig. 6(a)–(c) respectively. The diamond burnished surface has been considered for the measurement of surface topography. It was observed that in the cryogenic environment, peak to valley height was substantially reduced in contrast with MQL and dry environments. The reason is minimal thermal distortion has been observed on the cryogenic diamond burnished surface because of the constant spraying of LN2 in the burnishing zone. Hence the surface roughness achieved in the cryogenic environment was minimum. However, the other
Fig. 6. The surface topography observed at burnishing speed of 47 m/min, burnishing feed of 0.065 mm/rev and burnishing force of 125 N in (a) Cryogenic, (b) MQL and (c) Dry environments. 568
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Fig. 7. Variation of surface hardness at varying (a) burnishing speed (b) burnishing feed and (c) burnishing force in the cryogenic, MQL and dry environments.
environment. It is believed that the MQL usage will lead to tribological improvement along with the temperature reduction [33]. Latent heat developed in the burnishing zone will be extracted by the constant supply of MQL. The tool life will be improved because of the reduction in the friction generated in the burnishing zone [34,35]. Wear rate of the tool can be minimized which also helps in improving the tool life. The surface quality of the component can be enhanced with the proper usage of MQL during diamond burnishing. Moreover, the fine droplets of the oil will be evaporated which reduces the damage to the health and disposal problems can be overcome by the effective use of MQL in the manufacturing industries. Therefore it would be a better choice to improve the performance of the components when compared to the dry environment. In a dry environment because of the absence of the lubrication, the temperature at the tool and workpiece interface increases which causes friction and thermal softening. Hence the surface hardness recorded for the dry environment is less than cryogenic and MQL which has been shown in Fig. 7(a)–(c) for varying burnishing speed, burnishing feed and burnishing force respectively.
during the burnishing process. 3.4.2. Effect of burnishing feed and cryogenic cooling on surface hardness Fig. 7(b) illustrates the variation of surface hardness with burnishing feed. The decrease in the surface hardness of the material was noted at burnishing speed of 47 m/min, burnishing force of 125 N and varying burnishing feed. The surface hardness of the diamond burnished surface decreases with an increase in the burnishing feed from 0.048 mm/rev to 0.096 mm/rev. That’s because an increase in the burnishing feed causes a smaller amount of work hardening on the diamond burnished surface because of the minimum area subjected to plastic deformation [32]. The maximum surface hardness enhancement achieved in the cryogenic environment was 6% and 10% respectively when compared to MQL and dry environments. It is owing to the strain hardening effect observed in the cryogenic environment because of the continuous cooling effect of the LN2. 3.4.3. Effect of burnishing force and cryogenic cooling on surface hardness From Fig. 7(c) it was observed that the surface hardness constantly increases with an increase in the range of burnishing force from 50 N to 200 N. This trend has been observed for burnishing speed of 47 m/min, burnishing feed of 0.065 mm/rev and varying burnishing force. The reason for the continuous improvement of surface hardness is because of increase in the work hardening, and another reason may be due to the increased surface deformation during diamond burnishing [29,30]. The maximum surface hardness of 414 HV was noticed for burnishing force of 200 N in the cryogenic environment. The surface hardness of 388 HV and 375 HV respectively was observed in MQL and dry environments. In the cryogenic environment, an enhanced surface hardness was observed. It can be explained by the fact that the material becomes stronger and harder due to the impingement of LN2 at the toolworkpiece interface. Overall, from the above experimental findings, it was noticed that the effect of MQL has a crucial impact on the diamond burnishing process. The reason being, during the application of MQL, low quantity of lubricant is supplied to the burnishing zone in the form of mist which forms a fine spray. At this condition, the temperature in the burnishing zone is minimized. Hence an improved surface finish and surface hardness were achieved by MQL environment in contrast with the dry
3.5. Analysis of subsurface microhardness The subsurface microhardness of the burnished surface was studied to understand the effect of diamond burnishing process parameters on 17-4 PH stainless steel. Previous studies [36,37] related to burnishing shows that the subsurface microhardness of the material decreases as the depth from the surface increases. In the present study, the subsurface microhardness measurement has been carried out at a constant burnishing speed of 47 m/min, burnishing feed of 0.065 mm/rev, and burnishing force of 125 N which is represented in Fig.8(a). The measurement procedure is shown in Fig. 8(b). The subsurface microhardness of the bulk material was also measured to compare the variation of subsurface microhardness before and after diamond burnishing in different lubrication conditions. From Fig. 8(a), it is clear that the subsurface microhardness of the material decreases as the depth from the diamond burnished surface increases. In all the three environments the trend is observed to be the same. The reason for this may be due to the less shearing between the diamond tip and workpiece [24]. Another reason may be due to the lower strain induced by diamond burnishing [39]. As the depth increases beyond 130 μm, a minor difference has 569
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Fig. 9. Residual stress of the diamond burnished sample taken at burnishing speed of 47 m/min, burnishing feed of 0.065 mm/rev and burnishing force of 125 N in the cryogenic, MQL and dry environments.
parameters have been considered for the study. Distribution of the residual stress is depicted in Fig. 9. It has been observed that compressive residual stresses were induced after performing diamond burnishing. The highest compressive residual stress of −356 MPa has been observed in the cryogenic environment. The compressive residual stress of -298 MPa and−215 MPa was observed in MQL and dry environment respectively. The generation of the compressive residual stress enhances the fatigue resistance of the material by retarding the formation and growth of the cracks on the diamond burnished surface [13]. Most of the authors revealed that the burnishing force is one of the important parameters which influences the formation of compressive residual stress on the surface. When the applied burnishing force increases, it leads to increased plastic deformation on the surface layer [40].
Fig. 8. Subsurface microhardness observed at (a) burnishing speed of 47 m/ min, burnishing feed of 0.065 mm/rev and burnishing force of 125 N in the cryogenic, MQL and dry environments (b) measurement of subsurface microhardness.
4. Conclusions been observed, and it was also noticed that if the depth from the surface increases further, the subsurface microhardness of the material approaches the microhardness of the bulk material. The bulk material microhardness was found to be 340 HV. Just beneath the diamond burnished surface, the subsurface microhardness was observed to be maximum because of the work hardening process which has been experienced by the diamond burnished top surface layer of the material [38]. An improvement of 7% and 9% have been achieved in the cryogenic environment contrasted with MQL and dry environments respectively. This impact is because of the viable infiltration of cryogenic LN2 in the burnishing zone, creating significant declining of burnishing temperatures, reducing the friction between the contact surfaces [23].
The effect of diamond burnishing on surface integrity characteristics of 17-4 PH stainless steel was studied in the cryogenic, MQL and dry environments with a novel diamond burnishing tool. As per the findings from the present study, the following conclusions were drawn:
• Surface finish improvement of 33%–50%, 34–51%, and 25–40% •
3.6. Analysis of residual stress
•
Residual stress plays a significant role in enhancing the fatigue strength of the component [39]. The residual stresses induced on the surface of the diamond burnished samples were measured using X-Ray diffraction technique. Electrolytic polishing has been carried out to remove the layer of the material before measuring the residual stress. The equipment is initialized for about 15 min to warm up the system, and the X-ray tube is excited to an appropriate level before starting the measurements. The test piece is placed on a suitable fixture & the area where the stress analysis has to be carried out is focused manually in the equipment. The measurements were carried out by setting the parameters in accordance with the details of the test sample. The input settings considered for the present study are as follows: tube: Mn_KAlpha, wavelength: 2.103 Å, Bragg angle: 151.88˚, exposure time: 6 s, aperture: 1 mm, and D spacing: 1.0840460 Å. The residual stress measurement has been performed for burnishing speed of 47 m/min, burnishing feed of 0.065 mm/rev and burnishing force of 125 N. From the previous discussion about the surface roughness, surface hardness, and subsurface microhardness, it was noted that the above-mentioned process parameters yield a better result. Hence these levels of process
• • •
respectively was observed in the cryogenic environment in contrast with MQL and dry environment at all the levels of burnishing speed, burnishing feed and burnishing force. An improvement of 5%, 6%, and 6% was observed in the surface hardness in the cryogenic environment in contrast with MQL environment, and similarly, 7%, 10%, and 9% improvement were observed in the cryogenic environment in contrast with the dry environment. Highest subsurface microhardness was achieved in the cryogenic environment with a percentage improvement of 7% and 9% in contrast with MQL and dry environments. Compressive residual stresses of −356 MPa, −298 MPa, and −215 MPa respectively have been achieved in the cryogenic, MQL and dry environments. The proposed novel diamond burnishing tool shows a substantial improvement in the surface and subsurface characteristics in a cryogenic environment, which results in improved performance of the product compared to other burnishing environmental conditions. It has been recommended to use cryogenic environment for diamond burnishing process in the manufacturing of aerospace compressor blades and steam turbine engine parts to improve its surface integrity properties.
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Effect of working parameters on the surface integrity in cryogenic diamond burnishing of 17-4 PH stainless steel with a novel diamond burnishing tool
T
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Sachin Ba, , Narendranath Sa, D. Chakradharb a b
Department of Mechanical Engineering, National Institute of Technology Karnataka, Surathkal, India Department of Mechanical Engineering, Indian Institute of Technology Palakkad, Kerala, India
A R T I C LE I N FO
A B S T R A C T
Keywords: Cryogenic diamond burnishing MQL Dry Surface integrity 17-4 PH stainless steel
The productivity of the components is adversely affected by the poor surface integrity characteristics as a consequence of the generation of high temperature in the burnishing zone. The abundant use of conventional lubricants causes environmental pollution and health problems. To overcome these issues, cryogenic cooling has been used across the world to reduce the temperature generated in the burnishing zone. It is well known that most of the accidents which involve aero engines have revealed that the reason for this may be due to the failure of the first stage of compressor blades. Hence aerospace material, 17-4 precipitation hardenable (PH) stainless steel can be used in aero engines to minimize the failure occurring due to foreign object damage. In the present study, the effect of cryogenic diamond burnishing on the surface integrity characteristics such as surface roughness, surface hardness, surface morphology, surface topography, subsurface microhardness, and residual stress of 17-4 pH stainless steel have been investigated with a novel diamond burnishing tool and also it has been related to dry and minimum quantity lubrication (MQL) environments. From the experimental results of diamond burnishing process, surface roughness was observed to be reduced by 33%–50%, 34%–51% and 25%–40% in the cryogenic cooling environment in contrast with MQL and dry environments. Similarly, the surface hardness improvement in a cryogenic cooling environment was found to be 5%–7%, 6%–10%, and 6%–9%, in comparison with MQL and dry environments respectively.
1. Introduction A high-quality finishing of the mechanical parts is necessary to obtain the improved fatigue resistance and to attain a low friction ratio. Hence the finishing processes are turned out to be a major drive for industrial innovation all over the globe [1]. Diamond burnishing is one of the chipless finishing processes where the spherical tip of the tool made up of natural diamond, slides on the surface of the workpiece which causes plastic deformation. Directly after turning, the workpiece can be diamond burnished to obtain improved surface integrity properties. It is an economical and compatible process which can be applied on ferrous and nonferrous materials to obtain mirror-like surface finish. It has a higher level of efficiency when compared to grinding, lapping and polishing processes. The pH stainless steel is one of the interesting family of steels which can attain hardness up to 49 HRC [2]. One of the attractive features of 17-4 pH stainless steel is that it provides a great combination of high strength, ease of heat treatment, and excellent corrosion resistance which is not possible to find in any of the steel grades [3,4]. Hence, it
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could be a better choice to be used for the first set of aerospace compressor blades to avoid the problems arising due to the foreign object damage. It has a wide range of applications in the field of aircraft, chemical, petrochemical, food, metal and papermaking industries [5]. It develops more adhesion wear on the tool, and hence it can be categorized under difficult to cut materials [6]. The potential of slide burnishing was presented by Maximov et al. [7] in improving the residual stress, microhardness, and surface finish of high‑strength aluminum alloys. Korhonen et al. [8] observed an improvement in the surface hardness and surface finish while burnishing of Nitronic-50 HS using a diamond coated tip. Korzynski and Zarski [9] clarified the effect of the surface stereometric structure of AZ91 alloy by slide diamond burnishing. Chomienne et al. [10] studied the influence of ball-burnishing on residual stress profile of a 15-5 PH martensitic stainless steel. It was observed that a deep compressive layer would be formed after performing ball burnishing and burnishing force was found to be the most significant parameter. Okada et al. [11] proposed a novel method of a spherical 5 ° of freedom hybrid type mechanism. It was shown that it is possible to minimize the surface
Corresponding author. E-mail address: [email protected] (S. B).
https://doi.org/10.1016/j.jmapro.2019.01.051 Received 24 August 2018; Received in revised form 20 January 2019; Accepted 30 January 2019 1526-6125/ © 2019 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
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Fig. 1. Microstructure and EDS analysis of as received 17-4 PH stainless steel.
roughness of the flat and curved surfaces of the cuboid work material. Kuznetsov et al. [12] performed a study on strain accumulated in the subsurface of HRC5520Cr4 steel samples using nanostructuring burnishing. The influence of the parameters such as friction force and loading repetition was investigated. The experimental results verified the influence of both integral parameters on the performance of the steel sample. Maximov et al. [13] successfully applied slide burnishing on chromium-nickel steels to improve the surface integrity properties such as surface finish, residual stress, microhardness, wear resistance and fatigue strength. Jerez-Mesa et al. [14] investigated the influence of vibration-assisted ball burnishing on the topology of the AISI 1038 specimen. The bearing capacity has been observed to be improved, and its performance was compared with the conventional ball burnishing process. Toboła and Kania [15] investigated the effect of slide burnishing and nitriding phase on the composition and stress state of Sverker 21 and Vanadis 6 steel. The thickness of the effected region was increased in the slide burnished sample when compared to nitriding. The wear resistance of the sample was increased by the sequential turning-slide burnishing-nitriding process. Akkurt [16] compared the performance of drilling, turning, reaming, grinding, honing, and roller burnishing methods in surface finishing of AISI 304 austenitic stainless steel drilled holes. It was concluded that roller burnishing was successful in producing a superior quality of the drilled hole. Korzynski et al. [17] revealed that the slide diamond burnishing is one of the best methods to obtain the equilibrium surface texture of the valve stems. John et al. [18] carried out roller burnishing on EN-9 grade alloy steel and achieved a reduction in the surface roughness by 94.5% and improvement in the surface hardness by 41.7%. Sova et al. [19] conducted a study on the effect of sequential turning and burnishing on the residual stress and microstructure of 17-4 pH stainless steel cold spray deposits. It was revealed that turning was able to induce tensile residual stress and ball burnishing was successful in inducing compressive residual stress. Millions of workers get affected by working under different kinds of cutting fluids. Aerosol particles or mist are some of the hazardous elements which will be generated during the application of different types of cutting fluids during machining and which effects most of the human organs. Cryogenic has emerged as an alternative cutting fluid in the last two decades. Usually, liquid nitrogen (LN2) will be sprayed at the interface of the tool and workpiece. It is environmental friendly coolant when compared to other conventional coolants. During the burnishing process because of the pressure created in the burnishing zone, the temperature at that region increases. By the application of LN2, the temperature generated can be reduced which results in improved surface integrity properties of the material. Pu et al. [20] investigated the influence of cryogenic burnishing on AZ31B Mg alloy and confirmed an enhancement in corrosion resistance and surface hardness of the material. Tang et al. [21] clarified the corrosion resistance improvement along with the formation of uniform grains after cryogenic burnishing on titanium alloy. It was also claimed that surface roughness was minimized because of the effect of LN2. Huang et al. [22] proved that refined nano grains were formed during cryogenic burnishing on Al 7050-T7451 alloy. The hardness of the material was increased in a
cryogenic environment when compared to a dry environment. Pu et al. [23] reported the formation of ultrafine grain structure on Mg-Al-Zn alloy after performing cryogenic burnishing and also improved corrosion resistance was achieved. Yang et al. [24] explored the effect of cryogenic burnishing on Co-Cr-Mo biomaterial and attained improved surface integrity properties after cryogenic burnishing. 17-4 pH stainless steel finds applications in abundant key fields, so it is very much essential to perform a broad study on the diverse machinability perspectives. From the previous studies, it has been observed that inadequate literature is available on surface integrity investigation of diamond burnishing process under cryogenic, MQL and dry environments. There are not many evidence present in the literature regarding the potential of diamond burnishing in improving the quality of the surface of 17-4 PH stainless steel. Hence there is a necessity to understand the effect of control factors on diamond burnishing of 17-4 pH stainless steel under cryogenic, MQL and dry environments. To the author’s knowledge, not many kinds of literature are available on diamond burnishing process with the proposed novel diamond burnishing tool. Hence, the main objective of the current investigation is to study the influence of novel diamond burnishing tool on surface integrity properties of 17-4 PH stainless steel under cryogenic, MQL and dry environments. 2. Materials and method 2.1. Material selection The material under consideration for the present research work is 17-4 pH stainless steel procured in the form of a cylindrical bar of 32 mm diameter and 150 mm length. The chemical composition of the material is Ni - 4.62%; Cr - 18.53%; Cu - 2.96%; Si - 0.07%; C - 6.03%; P - 0.51% and Fe-Balance. The microstructure and the energy dispersive x-ray spectroscopy (EDS) analysis of as received material is as depicted in Fig. 1. The surface roughness after burnishing purely depends on the surface roughness before burnishing [25,26]. Hence the top layer of the cylindrical rod has been removed, and its size has been reduced to 30 mm diameter. AlTiN PVD coated KC5010 tungsten coated carbide insert was used for turning operation with a constant cutting velocity of 73 m/min, feed rate of 0.1 mm/rev, and depth of 0.25 mm. The average surface roughness and surface hardness before diamond burnishing were found to be 1.20 μm and 340 HV respectively. Based on the preliminary investigation and literature review the diamond burnishing process parameters have been selected. The process parameters and their levels are given in Table 1. 2.2. Experimental details The experiments have been carried out by ‘one-factor-at-the-time’ approach. ‘Kirloskar’ conventional lathe has been used in the present investigation to perform diamond burnishing. The surface roughness was measured by using ‘MITUTOYO’ make Talysurf ‘SJ3010′ model. Vickers hardness tester model ‘VM-120′ was used to measure the surface hardness. An average of three readings was recorded for both 565
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Table 1 Process parameters and their levels. Burnishing process parameters
Burnishing speed (S) Burnishing feed (f) Burnishing force (F)
Unit
m/min mm/rev N
Levels 1
2
3
4
5
21 0.048 50
30 0.055 88
47 0.065 125
73 0.079 163
113 0.096 200
Fig. 3. A novel diamond burnishing tool.
surface roughness and surface hardness. Three number of samples were tested under the same condition for one environment and for each sample the experimentation was carried out three times. Diamond burnished surface morphology was studied by ‘JEOL-JSM-638OLA’ model scanning electron microscope (SEM). The surface topography of the burnished surface has been obtained by ‘LESTOLS4100′ model confocal laser 3D surface tester. Residual stress has been measured by X-ray diffraction with MGR40 P stress measurement system make ‘PROTO.’ Microstructure and elemental composition of burnished samples have been measured by ‘Zeiss’ Scanning electron microscope, and ‘Oxford’ make ‘X-ACT’ type EDS. Vickers microhardness tester type ‘OMNI TECHMVHS-AUTO’ was used to measure the subsurface microhardness after diamond burnishing. Before measuring the microhardness of the specimen, it was subjected to cold mounting by acrylic powder and self-curing liquid. These samples were polished to obtain the exact indentation mark on the specimen. The diamond burnished samples were polished by emery papers of different grades and diamond paste to obtain the mirror finished surface. The present investigation has been carried out under three diamond burnishing modes namely cryogenic, MQL and dry environments. The flow rate of LN2 supplied in the burnishing zone was 0.45 kg/min. The schematic of cryogenic diamond burnishing set up is depicted in Fig. 2. Cryocan of ‘TA55′ model has been used for storing the LN2. The LN2 is maintained at a temperature of -196 °C inside the tank. LN2 was pressurized by applying suitable required pressure to the tank by the air compressor. It is supplied through the nozzle of 1 mm diameter at a pressure of 3 bar, and it is directed towards the tool-workpiece interface. ‘DAOML - 2/ PS / FS/’MQL set up has been used for the present research work. The oil mist was supplied through the external nozzle at a flow rate of 70 ml/h.
diamond burnishing tool for carrying out the diamond burnishing experiments. The tool contains two parts. The first one is the diamond stem and the second part is a shank. The stem of the tool contains a spherical diamond tip. The modification has been done in such a way that the stem of the tool can be removed easily from the shank by using button head screw without removing the tool from the fixed position. The movement of the stem will compress the spring which can be used to measure the applied burnishing force. In the novel diamond burnishing tool, heavy duty springs have been used with an increased number of coils whereas in conventional tool light duty springs have been used. These springs are capable of absorbing any possible vibration induced by the machine bed and also in minimizing the positioning error of the diamond burnishing tool. To transmit the burnishing force to the tool and also for the easy movement of the spring inside the tool, spring guide has been used. The square shank of the conventional tool has larger overhang while the newly modified tool has a better reach with smaller overhang. Attachment to the conventional lathe or CNC machine has become easy because of the extra grip provided with a newly designed tool. Dowel pin has been attached to the tool for the measurement of the deflection of the spring, and it was not present in the conventional tool where the measurement of burnishing force was difficult in contrast with the novel diamond burnishing tool. When the burnishing force is applied to the tool, the deflection readings of the spring was measured by a dial gauge. Whereas in the conventional tool the measurement of the deflection was difficult due to the absence of a dowel pin. In the preliminary experimentation and from the literature, it was perceived that a spherical diamond tip of the moderate radius would help to improve surface hardness and surface finish of the material. Hence in the present research work, a spherical diamond tip of radius 3.5 mm was used. The length of the stem of the tool has been reduced to avoid more stress acting on the tool while applying burnishing force.
2.3. Novel diamond burnishing tool 3. Results and discussion
To fulfill the requirements of the diamond burnishing process and to overcome the drawbacks faced by the manufacturers while using a conventional tool, a novel diamond burnishing tool has been used in the present investigation. Fig. 3 shows the specially designed and fabricated
In the present study, the performance of a novel diamond burnishing tool on surface integrity properties of 17-4 PH stainless steel was investigated. The surface integrity properties which have been considered for further study are surface roughness, surface hardness, surface morphology, surface topography, subsurface microhardness, and residual stress. 3.1. Analysis of surface roughness 3.1.1. Effect of burnishing speed and cryogenic cooling on surface roughness Performance of the mechanical components purely depends on the quality of the burnished surface of the material. From Fig. 4(a), it is noted that the surface roughness decreases from a burnishing speed of 21 m/min to 47 m/min and further increase in the burnishing speed from 47 m/min to 113 m/min leads to an increase in the surface roughness. The reason being, at lower burnishing speed the temperature generated in the burnishing zone will be reduced due to the constant spraying of LN2 and as the burnishing speed increases the temperature increases which results in possible chattering and is the reason for an increase in the surface roughness [27]. In MQL environment oil
Fig. 2. Schematic of cryogenic diamond burnishing. 566
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Fig. 4. Variation of surface roughness at varying (a) burnishing speed (b) burnishing feed and (c) burnishing force in the cryogenic, MQL and dry environments.
3.1.3. Effect of burnishing force and cryogenic cooling on surface roughness As indicated in Fig. 4(c), the surface roughness decreases at a lower range of burnishing force and a further increase in the burnishing force from 125 N to 200 N leads to an increase in the surface roughness. The reason for this variation in the surface roughness may be because of the incomplete plastic deformation of the asperities, which leads to decreased surface roughness at the lower burnishing force. The repeated plastic deformation on the surface of the workpiece results in increased work hardening at a higher range of burnishing force which causes flaking on the surface, and hence the surface finish deteriorates [29,30]. The surface roughness in the cryogenic environment is minimum when compared to all other environments because spraying of LN2 in the burnishing zone prevents the chemical and mechanical degradation of the burnished surface. Minimum surface roughness recorded was 0.03 μm in the cryogenic environment. It was found that the surface roughness was reduced by 25% and 40% in the cryogenic environment in contrast with MQL and dry environments respectively.
mist is sprayed at the workpiece-tool interface which reduces the temperature in the burnishing zone. In a dry environment because of the absence of lubrication the surface roughness recorded was higher than the other two environments. Another reason to be noted is that the material transformation takes place between the tool and the workpiece which results in maximizing the surface roughness at higher burnishing speed [28]. All the surface roughness measurements were carried out at a constant burnishing feed of 0.065 mm/rev and burnishing force of 125 N. The variation of burnishing speed was between 21 m/min to 113 m/min. In all the three environments similar trend has been observed for surface roughness. The lowest surface roughness was recorded for a burnishing speed of 47 m/min. An improvement of 33% was observed in the cryogenic environment in contrast with MQL environment. Similarly, 50% improvement was observed when compared to the dry environment.
3.1.2. Effect of burnishing feed and cryogenic cooling on surface roughness Fig. 4(b) indicates that the surface roughness decreases with an increase in the burnishing feed up to 0.055 mm/rev. The reason for this decrease could be elucidated by the fact that at a lower level of burnishing feed, the consecutive traces of the diamond tip on the surface of the workpiece will be small since the tool moves slowly over the workpiece [29]. As there is an increase in the burnishing feed from 0.055 mm/rev, a sudden increase in the surface roughness has been observed. The reason being, at upper limits of burnishing feed, the space between consecutive traces of the diamond tip increases. Another reason may be due to the minimum time available to the diamond tip to clear the bulged edges of the former traces [29]. The feed marks have been generated at the higher burnishing feed which can be seen from Fig. 5(b) and (c). The variation in the cryogenic environment is observed due to the splashing of the LN2 in the burnishing zone leads to lower coefficient of friction and also minimum vibration has been observed which leads to minimum feed marks on the burnished specimen. In all the three environments similar trend has been observed. The cryogenic environment has produced lowest surface roughness when compared to MQL and dry environments. The percentage of reduction was found to be 34% and 51% in contrast with MQL and dry environments respectively.
3.2. Analysis of surface morphology The diamond burnished surface morphology has been shown in Fig. 5(a), (b) and (c). The SEM images were obtained at the burnishing speed of 47 m/min, burnishing feed of 0.065 mm/rev and burnishing force of 125 N. The SEM images of the diamond burnished surface clearly show that uniform surface has been formed after diamond burnishing in the cryogenic environment. The cryogenic diamond burnished surface has the most regular surface in comparison with the MQL and dry environment which has been shown in Fig. 5(a). Uniform surface was observed in the cryogenic environment because of the presence of the cooling effect of LN2 at the interface of the tool and the workpiece. It results in the easy flow of the material and because of which the voids have been filled. The effect of feed marks was reduced in the case of cryogenic diamond burnishing due to the cooling effect of the LN2 in the burnished zone. In the previous discussion about the surface roughness, it was noticed that the surface roughness achieved for the cryogenic environment was minimum in contrast with MQL and dry environments. Similar observations have been made in Fig. 5(a). It was found that the feed marks have been generated and a similar effect has been observed in the SEM images of MQL environment which can be seen from Fig. 5(b). Micro voids have been observed in MQL 567
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Fig. 5. Surface morphology of the diamond burnished surface observed at burnishing speed of 47 m/min, burnishing feed of 0.065 mm/rev and burnishing force of 125 N in (a) Cryogenic (b) MQL and (c) Dry environments.
environments have shown increased peak to valley height because of the presence of higher temperature in the burnishing zone. From the results of SEM images and surface topography, it is pragmatic that cryogenic diamond burnishing yields improved surface finish which helps to improve the performance of the product in contrast with other working environments.
environment because of the improper deposition of the material in the voids and also an easy flow of the metal has been suppressed in MQL environment in contrast with the cryogenic environment. The splashing of the oil mist in the burnishing zone reduces the heat generated, and henceforth the surface roughness has been minimized in comparison with the dry environment. However, because of the absence of lubrication in a dry environment, the presence of feed marks and voids were visible as shown in Fig. 5(c). Micro cracks have been observed in the dry environment because of the excess heat produced in the burnishing zone due to the absence of lubrication.
3.4. Analysis of surface hardness 3.4.1. Effect of burnishing speed and cryogenic cooling on surface hardness The surface hardness variation concerning varying burnishing speed reveals that the surface hardness of the material decreases continuously when there is an increase in the burnishing speed. The temperature at the tool and workpiece interface increases as the burnishing speed increases, and also at higher burnishing speed, the chattering has been induced due to which the surface hardness decreases [31]. At a constant burnishing feed of 0.065 mm/rev and burnishing force of 125 N, the above trend has been achieved. The variation of the surface hardness with burnishing speed is represented in Fig. 7(a). The surface hardness improvement of 5% and 7% was observed in the cryogenic environment when compared to MQL and dry environment at a burnishing speed of 21 m/min. An absolute improvement in the surface hardness in the cryogenic environment was observed due to the constant spraying of LN2 in the burnishing zone which reduces the temperature accumulated
3.3. Analysis of surface topography The 3D surface topography has been measured at the burnishing speed of 47 m/min, burnishing feed of 0.065 mm/rev and burnishing force of 125 N under all the three environments which are represented in Fig. 6(a)–(c) respectively. The diamond burnished surface has been considered for the measurement of surface topography. It was observed that in the cryogenic environment, peak to valley height was substantially reduced in contrast with MQL and dry environments. The reason is minimal thermal distortion has been observed on the cryogenic diamond burnished surface because of the constant spraying of LN2 in the burnishing zone. Hence the surface roughness achieved in the cryogenic environment was minimum. However, the other
Fig. 6. The surface topography observed at burnishing speed of 47 m/min, burnishing feed of 0.065 mm/rev and burnishing force of 125 N in (a) Cryogenic, (b) MQL and (c) Dry environments. 568
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Fig. 7. Variation of surface hardness at varying (a) burnishing speed (b) burnishing feed and (c) burnishing force in the cryogenic, MQL and dry environments.
environment. It is believed that the MQL usage will lead to tribological improvement along with the temperature reduction [33]. Latent heat developed in the burnishing zone will be extracted by the constant supply of MQL. The tool life will be improved because of the reduction in the friction generated in the burnishing zone [34,35]. Wear rate of the tool can be minimized which also helps in improving the tool life. The surface quality of the component can be enhanced with the proper usage of MQL during diamond burnishing. Moreover, the fine droplets of the oil will be evaporated which reduces the damage to the health and disposal problems can be overcome by the effective use of MQL in the manufacturing industries. Therefore it would be a better choice to improve the performance of the components when compared to the dry environment. In a dry environment because of the absence of the lubrication, the temperature at the tool and workpiece interface increases which causes friction and thermal softening. Hence the surface hardness recorded for the dry environment is less than cryogenic and MQL which has been shown in Fig. 7(a)–(c) for varying burnishing speed, burnishing feed and burnishing force respectively.
during the burnishing process. 3.4.2. Effect of burnishing feed and cryogenic cooling on surface hardness Fig. 7(b) illustrates the variation of surface hardness with burnishing feed. The decrease in the surface hardness of the material was noted at burnishing speed of 47 m/min, burnishing force of 125 N and varying burnishing feed. The surface hardness of the diamond burnished surface decreases with an increase in the burnishing feed from 0.048 mm/rev to 0.096 mm/rev. That’s because an increase in the burnishing feed causes a smaller amount of work hardening on the diamond burnished surface because of the minimum area subjected to plastic deformation [32]. The maximum surface hardness enhancement achieved in the cryogenic environment was 6% and 10% respectively when compared to MQL and dry environments. It is owing to the strain hardening effect observed in the cryogenic environment because of the continuous cooling effect of the LN2. 3.4.3. Effect of burnishing force and cryogenic cooling on surface hardness From Fig. 7(c) it was observed that the surface hardness constantly increases with an increase in the range of burnishing force from 50 N to 200 N. This trend has been observed for burnishing speed of 47 m/min, burnishing feed of 0.065 mm/rev and varying burnishing force. The reason for the continuous improvement of surface hardness is because of increase in the work hardening, and another reason may be due to the increased surface deformation during diamond burnishing [29,30]. The maximum surface hardness of 414 HV was noticed for burnishing force of 200 N in the cryogenic environment. The surface hardness of 388 HV and 375 HV respectively was observed in MQL and dry environments. In the cryogenic environment, an enhanced surface hardness was observed. It can be explained by the fact that the material becomes stronger and harder due to the impingement of LN2 at the toolworkpiece interface. Overall, from the above experimental findings, it was noticed that the effect of MQL has a crucial impact on the diamond burnishing process. The reason being, during the application of MQL, low quantity of lubricant is supplied to the burnishing zone in the form of mist which forms a fine spray. At this condition, the temperature in the burnishing zone is minimized. Hence an improved surface finish and surface hardness were achieved by MQL environment in contrast with the dry
3.5. Analysis of subsurface microhardness The subsurface microhardness of the burnished surface was studied to understand the effect of diamond burnishing process parameters on 17-4 PH stainless steel. Previous studies [36,37] related to burnishing shows that the subsurface microhardness of the material decreases as the depth from the surface increases. In the present study, the subsurface microhardness measurement has been carried out at a constant burnishing speed of 47 m/min, burnishing feed of 0.065 mm/rev, and burnishing force of 125 N which is represented in Fig.8(a). The measurement procedure is shown in Fig. 8(b). The subsurface microhardness of the bulk material was also measured to compare the variation of subsurface microhardness before and after diamond burnishing in different lubrication conditions. From Fig. 8(a), it is clear that the subsurface microhardness of the material decreases as the depth from the diamond burnished surface increases. In all the three environments the trend is observed to be the same. The reason for this may be due to the less shearing between the diamond tip and workpiece [24]. Another reason may be due to the lower strain induced by diamond burnishing [39]. As the depth increases beyond 130 μm, a minor difference has 569
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Fig. 9. Residual stress of the diamond burnished sample taken at burnishing speed of 47 m/min, burnishing feed of 0.065 mm/rev and burnishing force of 125 N in the cryogenic, MQL and dry environments.
parameters have been considered for the study. Distribution of the residual stress is depicted in Fig. 9. It has been observed that compressive residual stresses were induced after performing diamond burnishing. The highest compressive residual stress of −356 MPa has been observed in the cryogenic environment. The compressive residual stress of -298 MPa and−215 MPa was observed in MQL and dry environment respectively. The generation of the compressive residual stress enhances the fatigue resistance of the material by retarding the formation and growth of the cracks on the diamond burnished surface [13]. Most of the authors revealed that the burnishing force is one of the important parameters which influences the formation of compressive residual stress on the surface. When the applied burnishing force increases, it leads to increased plastic deformation on the surface layer [40].
Fig. 8. Subsurface microhardness observed at (a) burnishing speed of 47 m/ min, burnishing feed of 0.065 mm/rev and burnishing force of 125 N in the cryogenic, MQL and dry environments (b) measurement of subsurface microhardness.
4. Conclusions been observed, and it was also noticed that if the depth from the surface increases further, the subsurface microhardness of the material approaches the microhardness of the bulk material. The bulk material microhardness was found to be 340 HV. Just beneath the diamond burnished surface, the subsurface microhardness was observed to be maximum because of the work hardening process which has been experienced by the diamond burnished top surface layer of the material [38]. An improvement of 7% and 9% have been achieved in the cryogenic environment contrasted with MQL and dry environments respectively. This impact is because of the viable infiltration of cryogenic LN2 in the burnishing zone, creating significant declining of burnishing temperatures, reducing the friction between the contact surfaces [23].
The effect of diamond burnishing on surface integrity characteristics of 17-4 PH stainless steel was studied in the cryogenic, MQL and dry environments with a novel diamond burnishing tool. As per the findings from the present study, the following conclusions were drawn:
• Surface finish improvement of 33%–50%, 34–51%, and 25–40% •
3.6. Analysis of residual stress
•
Residual stress plays a significant role in enhancing the fatigue strength of the component [39]. The residual stresses induced on the surface of the diamond burnished samples were measured using X-Ray diffraction technique. Electrolytic polishing has been carried out to remove the layer of the material before measuring the residual stress. The equipment is initialized for about 15 min to warm up the system, and the X-ray tube is excited to an appropriate level before starting the measurements. The test piece is placed on a suitable fixture & the area where the stress analysis has to be carried out is focused manually in the equipment. The measurements were carried out by setting the parameters in accordance with the details of the test sample. The input settings considered for the present study are as follows: tube: Mn_KAlpha, wavelength: 2.103 Å, Bragg angle: 151.88˚, exposure time: 6 s, aperture: 1 mm, and D spacing: 1.0840460 Å. The residual stress measurement has been performed for burnishing speed of 47 m/min, burnishing feed of 0.065 mm/rev and burnishing force of 125 N. From the previous discussion about the surface roughness, surface hardness, and subsurface microhardness, it was noted that the above-mentioned process parameters yield a better result. Hence these levels of process
• • •
respectively was observed in the cryogenic environment in contrast with MQL and dry environment at all the levels of burnishing speed, burnishing feed and burnishing force. An improvement of 5%, 6%, and 6% was observed in the surface hardness in the cryogenic environment in contrast with MQL environment, and similarly, 7%, 10%, and 9% improvement were observed in the cryogenic environment in contrast with the dry environment. Highest subsurface microhardness was achieved in the cryogenic environment with a percentage improvement of 7% and 9% in contrast with MQL and dry environments. Compressive residual stresses of −356 MPa, −298 MPa, and −215 MPa respectively have been achieved in the cryogenic, MQL and dry environments. The proposed novel diamond burnishing tool shows a substantial improvement in the surface and subsurface characteristics in a cryogenic environment, which results in improved performance of the product compared to other burnishing environmental conditions. It has been recommended to use cryogenic environment for diamond burnishing process in the manufacturing of aerospace compressor blades and steam turbine engine parts to improve its surface integrity properties.
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