Search results for: Machining stability.

Authors: Xie Kefeng, Zhang He

Abstract:

For the stability and control demand of offshore small floating platform, a 2-HUS/U parallel mechanism was presented as offshore platform. Inverse kinematics was obtained by institutional constraint equation, and the dynamic model of offshore 2-HUS/U parallel platform was derived based on rigid body’s Lagrangian method. The equivalent moment of inertia, damping and driving force/torque variation of offshore 2-HUS/U parallel platform were analyzed. A numerical example shows that, for parallel platform of given motion, system’s equivalent inertia changes 1.25 times maximally. During the movement of platform, they change dramatically with the system configuration and have coupling characteristics. The maximum equivalent drive torque is 800 N. At the same time, the curve of platform’s driving force/torque is smooth and has good sine features. The control system needs to be adjusted according to kinetic equation during stability and control and it provides a basis for the optimization of control system.

Keywords: 2-HUS/U platform, Dynamics, Lagrange, Parallel platform.

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Authors: G. Kehl, P. Wagner

Abstract:

A novel simulation method to determine the displacements of machine tools due to thermal factors is presented. The specific characteristic of this method is the employment of original CAD data from the design process chain, which is interpreted by an algorithm in terms of geometry-based allocation of convection and radiation parameters. Furthermore analogous models relating to the thermal behaviour of machine elements are automatically implemented, which were gained by extensive experimental testing with thermography imaging. With this a transient simulation of the thermal field and in series of the displacement of the machine tool is possible simultaneously during the design phase. This method was implemented and is already used industrially in the design of machining centres in order to improve the quality of herewith manufactured workpieces.

Keywords: Accuracy, design process, finite element analysis, machine tools, thermal simulation.

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Authors: Smko Zangana, Ergun Ercelebi

Abstract:

The alternating current is the main power in all industries and other aspects especially for the short and mid distances, but as far as long a distance which exceeds 500 KMs, using the alternating current technically will face many difficulties and more costs because it's difficult to control the current and also other restrictions. Therefore, recently those reasons led to building transmission lines HVDC to transmit power for long distances. This document presents technical comparison and assessments for power transmission system among distances either ways and studying the stability of the system regarding the proportion of losses in the actual power sent and received between both sides in different systems and also categorizing filters used in the HVDC system and its impact and effect on reducing Harmonic in the power transmission. MATLAB /Simulink simulation software is used to simulate both HVAC & HVDC power transmission system topologies.

Keywords: HVAC power system, HVDC power system, power system simulation (MATLAB), the alternating current, voltage stability.

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Authors: Ivan Balázs, Jindřich Melcher

Abstract:

Metal thin-walled members have been widely used in building industry. Usually they are utilized as purlins, girts or ceiling beams. Due to slenderness of thin-walled cross-sections these structural members are prone to stability problems (e.g. flexural buckling, lateral torsional buckling). If buckling is not constructionally prevented their resistance is limited by buckling strength. In practice planar members of roof or wall cladding can be attached to thin-walled members. These elements reduce displacement of thin-walled members and therefore increase their buckling strength. If this effect is taken into static assessment more economical sections of thin-walled members might be utilized and certain savings of material might be achieved. This paper focuses on problem of determination of critical load of steel thin-walled beams with lateral continuous restraint which is crucial for lateral torsional buckling assessment.

Keywords: Beam, buckling, numerical analysis, stability, steel.

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Authors: S. Tangjitsitcharoen

Abstract:

The chatter is one of the major limitations of the productivity in the ball end milling process. It affects the surface roughness, the dimensional accuracy and the tool life. The aim of this research is to propose the new system to detect the chatter during the ball end milling process by using the wavelet transform. The proposed method is implemented on the 5-axis CNC machining center and the new three parameters are introduced from three dynamic cutting forces, which are calculated by taking the ratio of the average variances of dynamic cutting forces to the absolute variances of themselves. It had been proved that the chatter can be easier to detect during the in-process cutting by using the new parameters which are proposed in this research. The experimentally obtained results showed that the wavelet transform can provide the reliable results to detect the chatter under various cutting conditions.

Keywords: Ball end milling, wavelet transform, fast fourier transform, chatter.

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Authors: T. K N. Hoang, P. A. Tuan, R. Finsy, L. Deriemaeker

Abstract:

The pigments covered by film-forming polymers have opened a prospect to improve the quality of water-based printing inks. In this study such pigments were prepared by the initiated polymerization of styrene and methacrylate derivative monomers in the aqueous pigment dispersions. The formation of polymer films covering pigment cores depends on the polymerization time and the ratio of pigment to monomers. At the time of 4 hours and the ratio of 1/10 almost pigment particles are coated by the polymer. The formed polymer covers of pigments have the average thickness of 5.95 nm. The size increasing percentage of the coated particles after a week is 4.5 %, about fourteen-fold lower than of the original ones. The obtained results indicate that the coated pigments are improved dispersion stability in water medium along with a guarantee for the optical colour.

Keywords: Aqueous pigment dispersion stability, colored resin particles, emulsion polymerization, water based ink.

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Authors: Dimitrios Koukopoulos

Abstract:

In this work, we study the impact of dynamically changing link slowdowns on the stability properties of packetswitched networks under the Adversarial Queueing Theory framework. Especially, we consider the Adversarial, Quasi-Static Slowdown Queueing Theory model, where each link slowdown may take on values in the two-valued set of integers {1, D} with D > 1 which remain fixed for a long time, under a (w, ¤ü)-adversary. In this framework, we present an innovative systematic construction for the estimation of adversarial injection rate lower bounds, which, if exceeded, cause instability in networks that use the LIS (Longest-in- System) protocol for contention-resolution. In addition, we show that a network that uses the LIS protocol for contention-resolution may result in dropping its instability bound at injection rates ¤ü > 0 when the network size and the high slowdown D take large values. This is the best ever known instability lower bound for LIS networks.

Keywords: Network stability, quality of service, adversarial queueing theory, greedy scheduling protocols.

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Authors: Ayman M. Alaskari, Samy E. Oraby, Abdulla I. Almazrouee

Abstract:

Coated tool inserts can be considered as the backbone of machining processes due to their wear and heat resistance. However, defects of coating can degrade the integrity of these inserts and the number of these defects should be minimized or eliminated if possible. Recently, the advancement of coating processes and analytical tools open a new era for optimizing the coating tools. First, an overview is given regarding coating technology for cutting tool inserts. Testing techniques for coating layers properties, as well as the various coating defects and their assessment are also surveyed. Second, it is introduced an experimental approach to examine the possible coating defects and flaws of worn multicoated carbide inserts using two important techniques namely scanning electron microscopy and atomic force microscopy. Finally, it is recommended a simple procedure for investigating manufacturing defects and flaws of worn inserts.

Keywords: AFM, Coated inserts, Defects, SEM.

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Authors: Siavash Asadi Ghajarloo

Abstract:

Nowadays predicting political risk level of country has become a critical issue for investors who intend to achieve accurate information concerning stability of the business environments. Since, most of the times investors are layman and nonprofessional IT personnel; this paper aims to propose a framework named GECR in order to help nonexpert persons to discover political risk stability across time based on the political news and events. To achieve this goal, the Bayesian Networks approach was utilized for 186 political news of Pakistan as sample dataset. Bayesian Networks as an artificial intelligence approach has been employed in presented framework, since this is a powerful technique that can be applied to model uncertain domains. The results showed that our framework along with Bayesian Networks as decision support tool, predicted the political risk level with a high degree of accuracy.

Keywords: Bayesian Networks, Data mining, GECRframework, Predicting political risk.

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Authors: Salman Pervaiz, Ibrahim Deiab, Amir Rashid, Mihai Nicolescu, Hossam Kishawy

Abstract:

Greenhouse gases (GHG) emissions impose major threat to global warming potential (GWP). Unfortunately manufacturing sector is one of the major sources that contribute towards the rapid increase in greenhouse gases (GHG) emissions. In manufacturing sector electric power consumption is the major driver that influences CO2 emission. Titanium alloys are widely utilized in aerospace, automotive and petrochemical sectors because of their high strength to weight ratio and corrosion resistance. Titanium alloys are termed as difficult to cut materials because of their poor machinability rating. The present study analyzes energy consumption during cutting with reference to material removal rate (MRR). Surface roughness was also measured in order to optimize energy consumption.

Keywords: Energy Consumption, CO2 Emission, Ti6Al4V.

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Authors: X. Mamaqi, J.Miguel, P. Olave

Abstract:

The aim of this paper is to provide an empirical evidence about the effects that the management of continuous training have on employability (or employment stability) in the Spanish labour market. With this purpose a binary logit model with interaction effect is been used. The dependent variable includes two situations of the active workers: continuous and discontinuous employability. To distinguish between them an Employability Index Stability (ESI) was calculated taking into account two factors: time worked and job security. Various aspects of the continuous training and personal workers data are used as independent variables. The data obtained from a survey of a sample of 918 employed have revealed a relationship between the likelihood of continuous employability and continuous training received. The empirical results support the positive and significant relationship between various aspects of the training provided by firms and employability likelihood of the workers, postulate alike from a theoretical point of view.

Keywords: training management, employability/employmentstability, binary logit model, interaction effect, Spanish marketlabour.

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Authors: C. C. Lv, Y. L. Sun, D. W. Zuo

Abstract:

Cemented carbide balls are usually implemented in industry under the environment of high speed, high temperature, corrosiveness and strong collisions. However, its application is limited due to high fabrication cost, processing efficiency and quality. A novel eccentric lapping method with two rotatable lapping plates was proposed in this paper. A mathematical model was constructed to analyze the influence of each design parameter on this lapping method. To validate this new lapping method, an orthogonal experiment was conducted with cemented carbide balls (YG6). The simulation model was verified and the optimal lapping parameters were derived. The results show that the surface roundness of the balls reaches to 0.65um from 2um in 1 hour using this lapping method. So, using this novel lapping method, it can effectively improve the machining precision and efficiency of cemented carbide balls.

Keywords: Cemented carbide balls, eccentric lapping, high precision, lapping tracks, V-groove.

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Authors: Dimitrios Koukopoulos

Abstract:

In this work, we study the impact of dynamically changing link slowdowns on the stability properties of packetswitched networks under the Adversarial Queueing Theory framework. Especially, we consider the Adversarial, Quasi-Static Slowdown Queueing Theory model, where each link slowdown may take on values in the two-valued set of integers {1, D} with D > 1 which remain fixed for a long time, under a (w, p)-adversary. In this framework, we present an innovative systematic construction for the estimation of adversarial injection rate lower bounds, which, if exceeded, cause instability in networks that use the LIS (Longest-in- System) protocol for contention-resolution. In addition, we show that a network that uses the LIS protocol for contention-resolution may result in dropping its instability bound at injection rates p > 0 when the network size and the high slowdown D take large values. This is the best ever known instability lower bound for LIS networks.

Keywords: Parallel computing, network stability, adversarial queuing theory, greedy scheduling protocols.

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Authors: Hossein Shahinzadeh, Ladan Darougaran, Ebrahim Jalili Sani, Hamed Yavari, Mahdi Mozaffari Legha

Abstract:

This paper present a new method for design of power system stabilizer (PSS) based on sliding mode control (SMC) technique. The control objective is to enhance stability and improve the dynamic response of the multi-machine power system. In order to test effectiveness of the proposed scheme, simulation will be carried out to analyze the small signal stability characteristics of the system about the steady state operating condition following the change in reference mechanical torque and also parameters uncertainties. For comparison, simulation of a conventional control PSS (lead-lag compensation type) will be carried out. The main approach is focusing on the control performance which later proven to have the degree of shorter reaching time and lower spike.

Keywords: Power system stabilizer (PSS), multi-machine power system, sliding mode control

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Authors: Renato Santos Paulinelli Raposo, Vinicius Resende Domingues, Manoel Porfirio Cordao Neto

Abstract:

Rapid drawdown is one of the cases referred to ground stability study in dam projects. Due to the complexity generated by the combination of loads and the difficulty in determining the parameters, analyses of rapid drawdown are usually performed considering the immediate reduction of water level upstream. The proposal of a simulation, considering the gradual reduction in water level upstream, requires knowledge of parameters about consolidation and those related to unsaturated soil. In this context, the purpose of this study is to understand the methodology of collection and analysis of parameters to simulate a rapid drawdown in dams. Using a numerical tool, the study is complemented with a hypothetical case study that can assist the practical use of data compiled. The referenced dam presents homogeneous section composed of clay soil, a height of 70 meters, a width of 12 meters, and upstream slope with inclination 1V:3H.

Keywords: Dam, GeoStudio, rapid drawdown, stability analysis.

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Authors: Barenten Suciu

Abstract:

Classical matrix calculus and Routh-Hurwitz stability conditions, applied to the snake-like motion of the conical wheel axle, lead to the conclusion that the hunting mode is inherently unstable, and its natural frequency is a complex number. In order to analytically solve such a complicated vibration model, either the inertia terms were neglected, in the model designated as geometrical, or restrictions on the creep coefficients and yawing diameter were imposed, in the so-called dynamical model. Here, an alternative solution is proposed to solve the hunting mode, based on the observation that the bullet train wheel axle is equipped with cylindrical wheels. One argues that for such wheel treads, the geometrical hunting is irrelevant, since its natural frequency becomes nil, but the dynamical hunting is significant since its natural frequency reduces to a real number. Moreover, one illustrates that the geometrical simplification of the wheel causes the stabilization of the hunting mode, since the characteristic quartic equation, derived for conical wheels, reduces to a quadratic equation of positive coefficients, for cylindrical wheels. Quite simple analytical expressions for the damping ratio and natural frequency are obtained, without applying restrictions into the model of contact. Graphs of the time-depending hunting lateral perturbation, including the maximal and inflexion points, are presented both for the critically-damped and the over-damped wheel axles.

Keywords: Bullet train, dynamical hunting, cylindrical wheels, damping, stability, creep, vibration analysis.

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Authors: R. Alipour, F. Nadjarian, A. Alinaghizade

Abstract:

Considering complexity of products, new geometrical design and investment tolerances that are necessary, measuring and dimensional controlling involve modern and more precise methods. Photo digitizing method using two cameras to record pictures and utilization of conventional method named “cloud points" and data analysis by the use of ATOUS software, is known as modern and efficient in mentioned context. In this paper, benefits of photo digitizing method in evaluating sampling of machining processes have been put forward. For example, assessment of geometrical integrity surface in 5-axis milling process and measurement of carbide tool wear in turning process, can be can be brought forward. Advantages of this method comparing to conventional methods have been expressed.

Keywords: photo digitizing, tool wear, geometrical integrity, cloud points

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Authors: O. P. Misra, Preety Kalra

Abstract:

It is well recognized that the green house gases such as Chlorofluoro Carbon (CFC), CH4, CO2 etc. are responsible directly or indirectly for the increase in the average global temperature of the Earth. The presence of CFC is responsible for the depletion of ozone concentration in the atmosphere due to which the heat accompanied with the sun rays are less absorbed causing increase in the atmospheric temperature of the Earth. The gases like CH4 and CO2 are also responsible for the increase in the atmospheric temperature. The increase in the temperature level directly or indirectly affects the dynamics of interacting species systems. Therefore, in this paper a mathematical model is proposed and analysed using stability theory to asses the effects of increasing temperature due to greenhouse gases on the survival or extinction of populations in a prey-predator system. A threshold value in terms of a stress parameter is obtained which determines the extinction or existence of populations in the underlying system.

Keywords: Equilibria, Green house gases, Model, Populations, Stability.

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Authors: Yuxin Chen, Qingyun Di, C. Dinis da Gama

Abstract:

In projects like waterpower, transportation and mining, etc., proving up the rock-mass structure and hidden tectonic to estimate the geological body-s activity is very important. Integrating the seismic results, drilling and trenching data, CSAMT method was carried out at a planning dame site in southwest China to evaluate the stability of a deformation. 2D and imitated 3D inversion resistivity results of CSAMT method were analyzed. The results indicated that CSAMT was an effective method for defining an outline of deformation body to several hundred meters deep; the Lung Pan Deformation was stable in natural conditions; but uncertain after the future reservoir was impounded. This research presents a good case study of the fine surveying and research on complex geological structure and hidden tectonic in engineering project.

Keywords: CSAMT Surveying, Deformation Stability.

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Authors: Xinhua Zhang, Kelin Li

Abstract:

In this paper, a class of impulsive BAM fuzzy cellular neural networks with distributed delays and reaction-diffusion terms is formulated and investigated. By employing the delay differential inequality and inequality technique developed by Xu et al., some sufficient conditions ensuring the existence, uniqueness and global exponential stability of equilibrium point for impulsive BAM fuzzy cellular neural networks with distributed delays and reaction-diffusion terms are obtained. In particular, the estimate of the exponential convergence rate is also provided, which depends on system parameters, diffusion effect and impulsive disturbed intention. It is believed that these results are significant and useful for the design and applications of BAM fuzzy cellular neural networks. An example is given to show the effectiveness of the results obtained here.

Keywords: Bi-directional associative memory, fuzzy cellular neuralnetworks, reaction-diffusion, delays, impulses, global exponentialstability.

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Authors: Sun Lim, Il-Kyun Jung

Abstract:

This paper describes a newly designed decentralized nonlinear control strategy to control a robot manipulator. Based on the concept of the nonlinear state feedback theory and decentralized concept is developed to improve the drawbacks in previous works concerned with complicate intelligent control and low cost effective sensor. The control methodology is derived in the sense of Lyapunov theorem so that the stability of the control system is guaranteed. The decentralized algorithm does not require other joint angle and velocity information. Individual Joint controller is implemented using a digital processor with nearly actuator to make it possible to achieve good dynamics and modular. Computer simulation result has been conducted to validate the effectiveness of the proposed control scheme under the occurrence of possible uncertainties and different reference trajectories. The merit of the proposed control system is indicated in comparison with a classical control system.

Keywords: Robot manipulator control, nonlinear controller, Lyapunov based stability, Interconnection compensation.

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Authors: Anuj Kumar Sharma, Amit Sharma, Kulbhushan Agnihotri

Abstract:

In this paper, a delayed plankton-nutrient interaction model consisting of phytoplankton, zooplankton and dissolved nutrient is considered. It is assumed that some species of phytoplankton releases toxin (known as toxin producing phytoplankton (TPP)) which is harmful for zooplankton growth and this toxin releasing process follows a discrete time variation. Using delay as bifurcation parameter, the stability of interior equilibrium point is investigated and it is shown that time delay can destabilize the otherwise stable non-zero equilibrium state by inducing Hopf-bifurcation when it crosses a certain threshold value. Explicit results are derived for stability and direction of the bifurcating periodic solution by using normal form theory and center manifold arguments. Finally, outcomes of the system are validated through numerical simulations.

Keywords: Plankton, Time delay, Hopf-bifurcation, Normal form theory, Center manifold theorem.

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Authors: A. M. Azad, M. Alam, C. M. Hussain

Abstract:

In this paper, we have presented the effect of varying time-delays on performance and stability in the single-channel multirate sampled-data system in hard real-time (RT-Linux) environment. The sampling task require response time that might exceed the capacity of RT-Linux. So a straight implementation with RT-Linux is not feasible, because of the latency of the systems and hence, sampling period should be less to handle this task. The best sampling rate is chosen for the sampled-data system, which is the slowest rate meets all performance requirements. RT-Linux is consistent with its specifications and the resolution of the real-time is considered 0.01 seconds to achieve an efficient result. The test results of our laboratory experiment shows that the multi-rate control technique in hard real-time operating system (RTOS) can improve the stability problem caused by the random access delays and asynchronization.

Keywords: Multi-rate, PID, RT-Linux, Sampled-data, Servo.

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Authors: Suman Kumar Saha, Rajib Kar, Durbadal Mandal, S. P. Ghoshal

Abstract:

This paper demonstrates the application of craziness based particle swarm optimization (CRPSO) technique for designing the 8th order low pass Infinite Impulse Response (IIR) filter. CRPSO, the much improved version of PSO, is a population based global heuristic search algorithm which finds near optimal solution in terms of a set of filter coefficients. Effectiveness of this algorithm is justified with a comparative study of some well established algorithms, namely, real coded genetic algorithm (RGA) and particle swarm optimization (PSO). Simulation results affirm that the proposed algorithm CRPSO, outperforms over its counterparts not only in terms of quality output i.e. sharpness at cut-off, pass band ripple, stop band ripple, and stop band attenuation but also in convergence speed with assured stability.

Keywords: IIR Filter, RGA, PSO, CRPSO, Evolutionary Optimization Techniques, Low Pass (LP) Filter, Magnitude Response, Pole-Zero Plot, Stability.

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Authors: Kyaw Myo Lin

Abstract:

This paper presents small signal stability study carried over the 140-Bus, 31-Machine, 5-Area MEPE system and validated on free and open source software: PSAT. Well-established linearalgebra analysis, eigenvalue analysis, is employed to determine the small signal dynamic behavior of test system. The aspects of local and interarea oscillations which may affect the operation and behavior of power system are analyzed. Eigenvalue analysis is carried out to investigate the small signal behavior of test system and the participation factors have been determined to identify the participation of the states in the variation of different mode shapes. Also, the variations in oscillatory modes are presented to observe the damping performance of the test system.

Keywords: Eigenvalue analysis, Mode shapes, MEPE test system, Participation factors, Power System oscillations.

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Authors: M. Saleem Khan, Khaled Benkrid

Abstract:

This paper presents the development techniques for a complete autonomous design model of an advanced train control system and gives a new approach for the implementation of multi-agents based system. This research work proposes to develop a novel control system to enhance the efficiency of the vehicles under constraints of various conditions, and contributes in stability and controllability issues, considering relevant safety and operational requirements with command control communication and various sensors to avoid accidents. The approach of speed scheduling, management and control in local and distributed environment is given to fulfill the dire needs of modern trend and enhance the vehicles control systems in automation. These techniques suggest the state of the art microelectronic technology with accuracy and stability as forefront goals.

Keywords: Multi-agents, Railway vehicle control system, autonomous design, Train management, Speed scheduling andcontrol.

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Authors: U. Ramesh Babu, V. Vijay Kumar Reddy, S. Tara Kalyani

Abstract:

The growth in the demand of electrical energy is leading to load on the Power system which increases the occurrence of frequent oscillations in the system. The reason for the oscillations is due to the lack of damping torque which is required to dominate the disturbances of Power system. By using FACT devices, such as Unified Power Flow Controller (UPFC) can control power flow, reduce sub-synchronous resonances and increase transient stability. Hence, UPFC is used to damp the oscillations occurred in Power system. This research focuses on adapting the neuro fuzzy controller for the UPFC design by connecting the infinite bus (SMIB - Single machine Infinite Bus) to a linearized model of synchronous machine (Heffron-Phillips) in the power system. This model gains the capability to improve the transient stability and to damp the oscillations of the system.

Keywords: Power System, UPFC, (ANFIS) Adaptive Neuro Fuzzy Inference System, transient, Low frequency oscillations.

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Authors: Sidhartha Panda, C. Ardil

Abstract:

Power system stabilizers (PSS) are now routinely used in the industry to damp out power system oscillations. In this paper, particle swarm optimization (PSO) technique is applied to coordinately design multiple power system stabilizers (PSS) in a multi-machine power system. The design problem of the proposed controllers is formulated as an optimization problem and PSO is employed to search for optimal controller parameters. By minimizing the time-domain based objective function, in which the deviation in the oscillatory rotor speed of the generator is involved; stability performance of the system is improved. The non-linear simulation results are presented for various severe disturbances and small disturbance at different locations as well as for various fault clearing sequences to show the effectiveness and robustness of the proposed controller and their ability to provide efficient damping of low frequency oscillations.

Keywords: Low frequency oscillations, Particle swarm optimization, power system stability, power system stabilizer, multimachine power system.

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Authors: Hany Osman, M. F. Baki

Abstract:

We address the balancing problem of transfer lines in this paper to find the optimal line balancing that minimizes the nonproductive time. We focus on the tool change time and face orientation change time both of which influence the makespane. We consider machine capacity limitations and technological constraints associated with the manufacturing process of auto cylinder heads. The problem is represented by a mixed integer programming model that aims at distributing the design features to workstations and sequencing the machining processes at a minimum non-productive time. The proposed model is solved by an algorithm established using linearization schemes and Benders- decomposition approach. The experiments show the efficiency of the algorithm in reaching the exact solution of small and medium problem instances at reasonable time.

Keywords: Transfer line balancing, Benders' decomposition, Linearization.

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Authors: Pavana Manvikar, G K Purohit

Abstract:

The functional performance of machined components, often, depends on surface topography, hardness, nature of stress and strain induced on the surface, etc. Invariably, surfaces of metallic components obtained by turning, milling, etc., consist of irregularities such as machining marks are responsible for the above. Surface finishing/coating processes used to produce improved surface quality/textures are classified as chip-removal and chip-less processes. Burnishing is chip-less cold working process carried out to improve surface finish, hardness and resistance to fatigue and corrosion; not obtainable by other surface coating and surface treatment processes. It is a very simple, but effective method which improves surface characteristics and is reported to introduce compressive stresses.

Of late, considerable attention is paid to post-machining, finishing operations, such as burnishing. During burnishing the micro-irregularities start to deform plastically, initially the crests are gradually flattened and zones of reduced deformation are formed. When all the crests are deformed, the valleys between the micro-irregularities start moving in the direction of the newly formed surface. The grain structure is then condensed, producing a smoother and harder surface with superior load-carrying and wear-resistant capabilities.

Burnishing can be performed on a lathe with a highly polished ball or roller type tool which is traversed under force over a rotating/stationary work piece. Often, several passes are used to obtain the work piece surface with the desired finish and hardness.

This paper presents the findings of an experimental investigation on the effect of ball burnishing parameters such as, burnishing speed, feed, force and number of passes; on surface roughness (Ra) and micro-hardness (Hv) of a 60/40 copper/zinc alloy, using a 2-level fractional factorial design of experiments (DoE). Mathematical models were developed to predict surface roughness and hardness generated by burnishing in terms of the above process parameters. A ball-type tool, designed and constructed from a high chrome steel material (HR_C=63 and Ra=0.012 µm), was used for burnishing of fine-turned cylindrical bars (0.68-0.78µm and 145Hv). They are given by,

 

Ra= 0.305-0.005X₁ - 0.0175X₂ + 0.0525X₄ + 0.0125X₁X₄ -0.02X₂X₄ - 0.0375X₃X₄

 

Hv=160.625 -2.37 5X₁ + 5.125X₂ + 1.875X₃ + 4.375X₄ - 1.625X₁X₄ + 4.375X₂X₄ - 2.375X₃X₄

 

High surface microhardness (175H_V) was obtained at 400rpm, 2passes, 0.05mm/rev and 15kgf., and high surface finish (0.20µm) was achieved at 30kgf, 0.1mm/rev, 112rpm and single pass. In other words, surface finish improved by 350% and microhardness improved by 21% compared to as machined conditions.

Keywords: Ball burnishing, surface roughness, micro-hardness.

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