Introduction of Burnishing process:
Burnishing a finish machining process is the plastic deformation of a surface due to sliding contact with another object.
Burnishing can be defined as a process in which a smooth but hard tool using sufficient pressure is rubbed on the surface of the metal.
Burnishing is a polishing and work hardening of a metallic surface will smooth and harden the surface, creating a finish which will last longer than one that hasn't been burnished.
Burnishing process works on a variety of different metals such as stainless steel, aluminium, cast iron, and brass, making available for today's manufacturers a wide variety of burnishing tools. Burnishing can eliminate secondary process which cuts down cycle time an ultimately saves money. Now, let's look at some common burning tool types.
Burnishing tools:
Burnishing process works on a variety of different metals such as stainless steel, aluminium, cast iron, and brass, making available for today's manufacturers a wide variety of burnishing tools. Burnishing can eliminate secondary process which cuts down cycle time an ultimately saves money. Now, let's look at some common burning tool types.
- Diamond burnishing tools :
This is one of the most versatile burnishing tools. It can be used on a variety of metals and can produce a dense, smooth surface. Setting up for diamond burning is fast and cost-effective, and secondary processes such as grinding are not needed. Overall, this processing tool is efficient and will show high-quality results.
- Multi-roll burnishing tools :
It can offer accurate sizing and can show significant improvements in the surface finish of steel and high ductility materials. They can produce in just one pass 2 to 8 Ra microinch finishes. It can be run on almost any machine tool, CNC or manual lathe. These burning tools can be fully interchanged with burning tools in the Madison style.
- Carbide roll burnishing tools :
It can be used so that there is no need for secondary operations this helps to reduce costs significantly. This tools remove any surface impurities and produce a 4 to 8 Ra micro inch finish in just one pass. Feature an economic tool life with the option to recondition the rolls.
Advantages of the burnishing process:
- Improves revolution size and finish such as cylinders and conical surfaces.
- It is possible to burn internal and external surfaces.
- Improves the hardness of the surface.
- Increases wear resistance and decrease fatigue and fight corrosion.
- It also eliminates the processes of grinding and honing that can be expensive.
- Mirror finish in one pass and accurate sizing, close tolerance and eliminate lapping and honing process too.
- Long tool life and no operator skill required.
- Machining time is short.
Most widely used burnishing process is Roller Burnishing.
Roller burnishing is a super-finishing process and cold rolling process without removal of metal. A set of rollers is used to roll on with adequate pressure on the component surface resulting in a fine surface through the planetary rotation of hardened rollers over a bored or turned metal surface.
In the roller burnishing operation compresses the projections into the indentation thus forming a smooth mirror finished surface. It is possible to burnish any material not exceeding 40 Rockwell Hardness C.
The result of this process is a mirror-like finish with a tough, work-hardened, wear and corrosion-resistant surface.
Roller burnishing:
Roller burnishing is a super-finishing process and cold rolling process without removal of metal. A set of rollers is used to roll on with adequate pressure on the component surface resulting in a fine surface through the planetary rotation of hardened rollers over a bored or turned metal surface.
In the roller burnishing operation compresses the projections into the indentation thus forming a smooth mirror finished surface. It is possible to burnish any material not exceeding 40 Rockwell Hardness C.
The result of this process is a mirror-like finish with a tough, work-hardened, wear and corrosion-resistant surface.
Advantages of roller burnishing process:
- Surface finish is good as a mirror Rz < 1 µm / Ra < 0.16 µm can be obtained.
- It is possible to achieve very close and consistent dimensional tolerance.
- Accurate sizing and short cycle time.
- Single-pass operation and very less cycle time are required to complete the job to required surface finish and tolerance.
- The surface hardens at the same time ensures that the processed surface to become stronger, and more slippery.
- Reduces reworks and rejections.
- No sawdust and residues occur so no noise and damage to the environment.
- It is too much economical, low spare part consumption and saves time, money and energy.
Application of Roller Burnishing Tools:
Bright tools are used in sectors such as
- Automobile
- Aircraft
- Defence
- Spacecraft
- Railways
- Textile
- Machine Tool
- Motors and Pump Industry
- Hydraulic and Pneumatic Farm Equipment
- Home Appliances