Simulation Of The Burnishing Process On Real Surface Structures

Burnishing is a finishing manufacturing process that provides the required surface integrity of metal parts. Precise process simulation enables optimization to guarantee the quality of the product. A literature review showed that most researches in this field have used an idealized smooth surface for simulations and have not considered the influence of surface roughness on the simulation results. However, for burnishing processes, the initial roughness has a measurable effect on the simulation quality. Hence, an innovative approach for the preparation of the FEM process model was developed. The approach based on reverse engineering. Using 3D scanning, models of the workpiece and the tool were created and imported in the process model. The developed approach was validated through a case study. The results of the simulation with surface roughness demonstrate a better compatibility to the real process than the results of the same simulation on the idealized surface. Hence, using this approach, it is possible to create a precise model of the process and achieve more qualitative result of the burnishing simulations.