Finite Element Analysis of Roller Burnishing Process

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 06 | June -2017 www.irjet.net p-ISSN: 2395-0072
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FINITE ELEMENT ANALYSIS OF ROLLER BURNISHING PROCESS
Shailesh Dadmal1, Prof. Vijay Kurkute2
1PG Student, Mechanical Department, Bharati Vidyapeeth University, College of Engineering, Pune,
Maharashtra, India,
2Associate Professor, Mechanical Department, Bharati Vidyapeeth University, College of Engineering, Pune,
Maharashtra, India
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Abstract – In today’s time, the manufacturing of machines
and other components with highly furnished surfaces are
becoming more and more important. Drasticattentionisbeing
given on the equality of the surface. Surface finishing is the
mandatory characteristic of any produced machine. The
operation, which can easily improve surface roughness of
machinery parts, is called as Burnishing Operation and it is
getting evolved day by day. It basically involves plastic
deformation of the material. It is a cold rolling process,
without any removal of metal from the work piece. An
assembly of roller or ball is used as the work tool on the work
piece with sufficient pressure applied on the work piece, and
hence the process get computes. Peaks get changed into
valleys and at last a highly polished mirror like surface is
obtained. In case of sliding surfaces, it enhances the life of the
material. This paper explains the finite element analysis of
roller burnishing process. Surface finishing has a prolonged
effect on every material. It is applied to implementasuccessful
hard roller burnishing process. The consequenceofburnishing
parameters along with surface integrity needs tobeevaluated
before actual functioning. In this paper we have presented a
process of developing a 2D model using transient structural
analysis of roller burnishing process. While doing finite
element analysis only force parameter will be considered.
Key Words: Surface Roughness, Surface Hardness, Finite
Element Analysis (FEA), Roller Burnishing Process
1. INTRODUCTION
There is a large significance of alternate energy sources like
solar and wind. In high time world of globalization and
urbanization, the performance of the machine is highly
dependent on dimensional accuracy, geometrical tolerance
and surface finish of the component. In order to obtain good
accuracy with proper matching of parts without any
tolerance requires a very good surface finishing.Thesurface
finishing procedure plays a very important role in
manufacturing industries for each kind of machinery part.
Lots of emphasis is given on the quality of surface forgetting
desired physical and mechanical properties.Overthespanof
last few years a lot of research is beingdoneon metal surface
finishing to increase the surface properties of themachinery
parts.
The metal finishing process are basically divided into two
main divisions as follows:
1. Based on Abrasives, like cutting action. For example,
Honing, lapping, buffing, polishing, grinding.
2. On plastic deformation of surface. For example,
burnishing, short peening, barrel rolling, short blasting etc.
Around the world there are number of several finishing
process that are used to obtain surface with requiredquality
properties. Whereas, burnishing is used widely for
processing external andinternal surfacesofmachineryparts.
In this procedure two types of tools can be used (1. One or
more balls made of hardened steel, 2. one or more rollers
made of harden steel). In case of balls sliding friction takes
place. Whereas in second case rolling friction takes place.
1.1 Burnishing Operation
In the burnishing operation, the surface properties of the
material changes as a result of plastic deformation process,
which produces a high surface finish by the rotation of tool
over the surface. The tool may further consist of a ball or a
roller as per requirement. We know that surface finishing is
a process which doesn’t involve removal of material. It
basically helps in minimizing the distance of peaks from its
mean and ultimately decreases the roughness of surface.
Fig 1: Basic Operation of Burnishing
1.2 Working Principle of Burnishing
Burnishing process is a highly flexible operation that
decreases surface irregularitiesandimprovesthedimension
of parts without any further requirement of tooling on
simply turning the workpiece into convention lathe.
It reduces the machinery cost, human effort and time
required for remounting of components. The tool used can
be a single ruler or multiple roller which are held in tool
post. This tool is mounted on the tool post of the lathe. When

the tool gets pressed against the rotating workpiece, the
frictional force comes in picture between the roller and the
workpiece. The direction of the rotation of the workpiece is
always opposite to that of the tool. Burnishing process is
sometimes also known as cold working process.
1.3 Process Parameters of Burnishing Operation
The burnishing operation can be control by the various
process parameters which are known as burnishingprocess
parameters. All these different process parameters need to
control and optimize to get the best results. The various
process parameters are as follows:
1. Burnishing speed
2. Feed Rate
3. Burnishing Force
4. Number of Passes
1.3.1 Burnishing Speed
The burnishing speed at which the work piece is rotated
during burnishing operation. The burnishing speed is given
to either work piece or burnishing tool. In Flat surface
burnishing operation, the burnishing tool rotated and work
piece remains stationary. Burnishing speed is mainly given
in Revolution / Minute or mm / Minute. Strength and
dimension of work piece decided the speed of burnishing
operation.
1.3.2 Feed Rate
Feed rate is the linear velocity with which tool is fed related
to work piece. The feed rate is generally measured in terms
of mm per revolutions.Theamountofsurfacefinishrequired
defines the feed rate. For high surface finish, the feed rate
should be minimum. So the feed rate should be optimizing
for the better surface finish.
1.3.3 Burnishing Force
The burnishing tool is pressed against work piece during
burnishing operation. The force exert by burnishing tool on
the work piece is known as the burnishing force. The
burnishing force acts perpendicular on the work piece
surface. In burnishing process, the burnishing force is very
important and most critical parameter among all other
parameter because surface roughness after burnishing
operation mainly depends on force with which the
burnishing tool is pressed against workpiece. The force
required during burnishingoperationshouldbehighenough
to modify surface asperities and to flow material frompeaks
into valleys. The burnishing force is mainly depending on
yield strength of material.
1.3.4 Number of tool passes
Sometimes the burnishing operation is repeatedly done on
work piece by using same process parameters. Due to this,it
helps to enhance the surface roughness. In some
applications, the number of tool passes may go up to several
number of times depending upon the surface roughness
required and strength of the work piece.
1.4 Surface Roughness
Surface of machinery components provides a link between
manufacturing and their variousfunctioninused.Ithasbeen
observed that 80% of machine failures are because of wear
of contact surfaces in meeting parts. The life of machine
parts can be increased by avoiding the wear of components.
Hence it is highly recommended to make the parts highly
smooth with no roughness on their boundariesor edges.Itis
basically the deviation in the direction of normal vector of
real surface from the ideal form. The rough surfaces usually
have high coefficient of friction as compared to the smooth
surface and they normally wear out rapidly as compared to
smooth surface.
Fig 2: Surface Profile
Advantages of Good surface finish are:
1. Excellent surface finish increases the wear resistance of
the workpiece in contact.
2. It reduces the friction between two workpiece.
3. Good surface finishes result in high cosmetic effect and
also increases the load carrying capacity. It also decreases
the corrosion and fatigue life of components.
2. LITERATURE SURVEY
M.H. El-Axir [1] studied the inﬂuence of different burnishing
conditions on both surface micro hardness and roughness:
namely, burnishing speed, force, feed, andnumberofpasses.
Initially roughness of about Ra 4.5 µm can be ﬁnished to a
roughness of 0.5 µm. A good correlation between the
experimental and predicted results derived from the model
was exhibited.

Partchapol Sartkulvanich [2] et all in this study, 2D and 3D
FEM models were established. Simulation results were
evaluated and compared to the experimental data.BothFEM
and experiments show the burnshing pressure is the most
influence, where high burnishing pressure less roughness
and more compresssive residual stress at the surface.
J.N. Malleswara Rao [3] et all in the present work,
experimental work is carried out to reduce the surface
roughness of a specially fabricated aluminumwork piece, by
roller burnishing process on lathe. FEA model is developed
to compare experimental results. The results are found to
coincide with the values got from the experimental readings,
and the variations are less than 10 %.
P.Saritha [4] states that Roller burnishing process is used to
get a good surface finish of materials such as aluminum and
mild steel. Their results obtained for contact stresses in a
roller burnishing process are found on using the different
theories and numerical methods. DifferentcontactModels of
the burnishing process are used in the present FEA analysis.
The Contact Analysis Prove to about 10 to 15% variation in
results.
B. Pattabhi Reddy [5] et all investigated surface
characteristics like SurfaceHardnessandSurfaceRoughness
of roller burnishing components are performed by
considering different parameterslikeSpeed,Feed,Force and
Passes. Analysis is performed by ANSYS software. The
Results from the ANSYS are compared withResultsobtained
from different theories and Contact Models of FEA analysis.
Prof. Ghodke A. P [6] et all reviwed effect of burnishing
process on behaviour of engineering materials. Two
important paramters to improve ductility of materials are
burnishing force and burnishing tool passes.Ascompared to
other surface finishing processes burnishing can givebetter
surface quality and dimensional accuracy.
3. WORKPIECE & EQUIPMENTS
3.1 Workpiece Material
Burnishing Operations make use of tuned aluminum
workpiece. It is used because it is very much ductile,
corrosive resistant, good conductor andverymuchavailable
in the form of round bars. This workpiece is specially
fabricated. The pre-determined chemical composition of
aluminum specimen (WT%) is as follows:
Table 1: Chemical Composition of the Al 6061
Fig 3: Workpiece
3.2 Major Equipment
The equipment used during the experimentation are listed
below:
1. Roller Burnishing tool
2. Surface Roughness Tester
Roller burnishing tool
The single roller burnishing tool which is used during
experimentation is shown in figure. It has following main
components:
1. Hard roller
2. Shank
3. High stiffness spring
To improve its hardness heat treated shank is made of mild
steel. The shank of roller burnishing tool has square cross
section (30mm * 30mm) which is hold in the tool holder.
Using a bolt and nut assembly is use provision to fix the
roller at the end of the square shank which looks similar to a
fork. Tool steel and high carbon high chromium steel is used
for manufacturing the roller of burnishing tool. These
materials made the roller of burnishingtool wearresistance,
toughness and high hardness.
Fig 4: Single roller burnishing tool
Basically care is taken in the design of the roller. The surface
of the roller is made to provide certain nose radius, so
eliminate sharp edges. After machining, the rollers are
subjected to heat treatment to improve the hardness. The
surface of the roller is cleaned by buffing to removethescale
deposited during heat treatment and with help of bolt and
nut the roller is fitted in the shank.
Mg Si Cu Zn Mn Cr Fe Ti
0.2 0.4-
0.8
0.15-
0.4
0.25 0.15 0.04-
0.35
0.7 0.1

Surface roughness tester
As a stylus instrument, we used surface roughness tester
(MITUTOYO Model -SJ211). The workingprincipleofsurface
roughness tester is based on moving the probe of tester on
surface whose roughness is to be measure. Generally, the
probe is made up of hard material to resist the wear as it is
continuously in contact with surface whose roughness is to
measure.
Fig 5: Surface Roughness Tester
4. EXPERIMENTAL SETUP
Burnishing process is a superfinishingprocessasburnishing
is super finishing operation which does not consist of
removal of material from work piece. These components
cannot be suitable to be burnished directly due to inherent
flaws like scaling, out of roundness, irregular diameter etc.
Fig 6: Experimental Setup
The wok piece should be undergoing through different
machining process, to make material free from surface
imperfections. Firstly, facing and turning operations are
carried out and after that work piece is burnished by using
single roller burnishing tool. Experimentation is conducted
on CNC lathe and for measurement of force we have used
dynamometer. The process of burnishing is well explained
below:
Burnishing Operation:
The main advantage of burnishing operation is that it saves
good amount of production time because there is no need to
remove the work piece from lathe machine and re-clamped
on some other machine. The roller burnishing tool is
clamped on the tool post of lathe machine which is fed
against work piece during burnishing operation.
Fig 7: Burnishing Operation
5. FINITE ELEMENT ANALYSIS
FEA allow us to evaluate a detailed and highly complex
structurer on a computer. While planning the structure. It is
also being known to increase the efficiency of structure that
were somewhat over designed for the time when FEA was
not available, the development of structures was highly
dependent on hand calculation. HC might lead to small
errors and this may result in significant change in design
which will increase the risk. With the help of FEA the weight
of a design can be decreased and there can be reduction in
number of prototype built.
ANSYS is a general purpose software it can be used for
almost every type of finite element analysis. In every
industry like electronics, automobiles, aerospace etc.ANSYS
program can be in two different modes i.e. interactive mode
or batch mode. The ANSYS major system is also organized
into logical grouping of related topics. The major ones are
main components, utility and referred. General steps for
solving any engineering problems using FEA:
1. Pre-Processing
2. Processing / Solution
3. Post-Processing
In ANSYS Workbench there are five main steps for the
transient structural analysis are as follows:
1. Engineering data
2. Geometry
3. Model
4. Set up
5. Solution
Engineering Data
In engineering data, we select the materials required for the
analysis which are used in study. In engineering data
sources, there are various data sources like general
materials, general non-linear materials, explicit materials,
hyper elastic materials, magnetic B-H curve, thermal
materials, fluid materials, composite material etc.andunder

these data sources their different material optionstochoose
the required material for analysis.
In this study, aluminum is used as work piecematerial hence
from engineering data source aluminum alloy which comes
under general materials. As weselect aluminummaterial the
workbench software will takes its physical material
properties automatically.
Geometry
In this we can make the geometry in software itself or can
import the geometry/model from any modelling software
like CATIA, CREO, Solid works etc. Forsimplegeometries we
can used this software but for completed real life problem
models are difficult to develop hence for this we have to
build the model in any modelling software and can import
the model in the ANSYS.
In this study, 2d FEM model is developed in ANSYSitselfasit
is a simple model. For FEM model wehaveassumedheight of
surface roughness peak as 3.2 µm and included angle of 80°.
For modelling we have select the line option from sketching
and drawn the line model as per assumptions, from line
model surface is developed using surface from sketches
which is in concept option. Now this surface created nine
times towards right side linearly using pattern option as
shown in fig 8.
Fig 8: 2D FEM Model / geometry
Model
After geometry next step is model. In this, we can give the
various parameters to the geometry like thickness also
assign the material if we choose more than two materials in
engineering data otherwise it will take structural steel since
it is a default material of ANSYS Workbench. After this we
can give the connections for the contacts between models
and finally we do the meshing tothegeometry byusingmesh
option. Meshing is a discretization of an object into nodes
and elements. For good meshing, mesh refinement thereare
various options like method, sizing, contact meshing,
refinement, face meshing, match control etc. we use these
options depending on the geometry shape and size. While
doing meshing we have to consider the parameters like
solution time, computer system on which we are doing the
analysis i.e., depending on the time constraint, computer
system etc. we do the meshing.
In this study, aluminum material isassignedforsurfacebody
(geometry) from material assignment option. Meshing is
done just by clicking on generate mesh option and it
automatically generates the mesh to the surface body as
shown in fig 9.
Fig 9: Model after Meshing
Setup
In this we give the boundary conditions depending on the
problem or application. There are various boundary
conditions like fixed support, force, pressure, displacement,
remote displacement, velocity and many othersrequiredfor
analysis.
In this study, fixed support and force are inserted for the
analysis. Fixed support is given at the bottom edge and side
edges of the model and Forces are given on all nine peaks in
vertically downward direction i.e., along y-axis as shown in
fig 10. Set of forces taken for analyses are 20N, 40N, 60N,
80N, 100N. Fig 10 shows the boundary conditions for 80N
force.
Fig 10: model after boundary conditions
Solution
Above all steps i.e. engineering data, geometry, model, setup
comes under pre-processing. In solution or processing we
have just to click on the solve icon. Software internally
carried out the matrix formation, multiplication, inversion
and solution for unknown e.g. displacement and then finds
the stress & strain for analysis. In solution we insert the
required results.

5.1 Results
After solution the next step in workbench is results. In this
we can see the required results of analysis like stress, strain,
displacement (total, directional) etc. also verification,
conclusions and thinking about what steps could be taken to
improve the design we can decide through results.
In this study, only the deformation of the model is found out
as a result since here we are interested in surface roughness
value after burnishing process.
- 20N Force
Fig 11: Deformation for 20N Force
- 40N Force
- 60N Force
- 80N Force
- 100N Force
- 80N (force deformed + undeformed model)
Fig 16: 80N force (deformed + undeformed model)
Force(N) Deformation
(µm)
Roughness
(µm)
20 2.0034 1.1966
40 2.3622 0.8378
60 2.5337 0.6663
80 2.6485 0.5515
100 2.7686 0.4314
Table 2: Results of FEA

6. RESULTS
Fig 17: Roughness Vs Force FEA Plot
Fig 18: Roughness Vs Force Experimental Plot
Fig 19: FEA Ra Plot Vs Experimental Ra Plot
Force
(N)
FEA Ra
(µm)
Experimental
Ra (µm)
%
Error
20 1.1966 1.1252 5.97
40 0.8378 0.8136 2.89
60 0.6663 0.6025 9.57
80 0.5515 0.5025 8.89
100 0.4314 0.4236 1.80
Table 3: FEA Plot Vs Experimental Plot
7. CONCLUSION
Finite Analysis was employed to evaluate effect of
burnishing force on the surface roughness of aluminium
alloy. As force increases, surface roughness decreases and
reaches to minimum value. When the Finite Element
Analysis is carried out it is found that the results are
coinciding with the values obtained from experimental
results. From the table, it is observed that the variations
obtained have less than 10 % error.
Discrepancies in comparison of results are due to the
following reasons:
1. Approximate MaterialsPropertiesusedinsimulationsince
text book values are different from Practice and
2. The modeling of contact by artificially creating peaks is
inadequate since thereareinnumerablepeakstobemodeled
in a statistical manner. The best approach is to adopt multi-
scale FEM methods.
ACKNOWLEDGEMENT
It gives me great honor and satisfaction in presenting this
comprehensive experimental study of “Finite Element
Analysis of Roller Burnishing Process”. I will always be
thankful to my project guide Prof. V.K.Kurkuteforhisadvice
and guidance in this work and his tireless support in
ensuring its completion. I would also like to express my
thanks to Mechanical Engineering Department and the
faculty members of P.G. (Mechanical Engineering) for their
precious support.
REFERENCES
[1] El-Axir, M. H. (2000) “An investigation into roller
burnishing”, International Journal of Machine Tool &
Manufacture, 40, 1603-1617.
[2] Partchapol Sartkulvanich, T. A. (AUGUST 2007)
“Finite Element Modelling of Hard Roller Burnishing:
An Analysis on the Effect of Process ParametersUpon
Surface Finish and Residual Stresses”, Journal of
Manufacturing Science and Engineering, Vol. 129,
705-716.
[3] J.N. Malleswara Rao, D. A. (2011) “Finite Element
Approach for the Prediction of Residual Stresses in
Aluminum Work Pieces Produced By Roller
Burnishing”, International Journal of Design and
Manufacturing Technology, Volume 2, 07-20.
[4] P.Saritha. (2014, January ) “A StudyOnAssessmentOf
Theories For Contact Stress Distribution At Roller-
Work Piece Contact In Roller Burnishing”,
International Journal of Science, Engineering and
Technology Research, Volume 3, 100-106.
[5] B. Pattabhi Reddy, C. S. (2015, November)
“Investigations in Contact Stress Analysis in Roller
Burnishing Process”, International Journal &Magzine
of Engineering, Technology, Management and
Resource, Volume 2, 1502-1516.
[6] Prof. Ghodke A. P., P. R. (2013, Mar-Apr) “Effect of
Burnishing Process on Behavior of Engineering
Materials - A Review”, IOSR- Journal of Mechnical and
Civil Engineering, Volume 5, 09-20.
[7] Malleswara Rao J. N.C(2011),
The effect of roller burnishing on surface hardness an

d surface roughness on mild steel specimens.
International Journal Of Applied Engineering Researc
h Dindigul, Volume 4, 777-785.
[8] R. G. Solanki, K. A. (2016, May- Jun). Parametric
Optimization of Roller BurnishingProcessforSurface
Roughness. IOSR Journal of Mechanical and Civil
Engineering , Volume 13, 21-26 .
[9] Nikhil Shinde, V. K. Kurkute (2016, November).
Optimization Of Single Roller Burnishing Operation
For Surface Roughness of Aluminium Alloy Using
Artificial Neural Network. International Journal of
Mechanical Engineering, 1289-1293.
[10] Ashish Deshmukh, P. (2015, July ). Analyasis and
Optimization of Roller Burnishing Process on
Cylindrical Surfacemicro Hardness of Aluminium
Alloy . International Journal of InnovativeResearchin
Science, Engineering and Technology, Vol. 4, 6044-
6055.
BIOGRAPHIES
I, Shailesh Dadmal, am a final year
M.Tech. student of Mechanical Dept. in
Bharati Vidyapeeth University, College
of Engineering, Pune.
I, Prof. Vijay Kurkute, am an Associate
Professor of Mechanical Dept.inBharati
Vidyapeeth University, College of
Engineering, Pune.

Finite Element Analysis of Roller Burnishing Process

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