A seminar report on LOW PLASTICITY BURNISHING
Low Plasticity Burnishing ppt
Oct 26, 2015
Low Plasticity Burnishing (LPB) is a state-of-the-art method of surface enhancement, which raises the burnishing to next level of sophistication and that can provide deep, stable surface compression for improved surface integrity characteristics. This paper reports an innovative approach, which was used to design and develop a new LPB tool. The performance of the LPB tool has been assessed on surface roughness and surface microhardness aspects of steels. This type of design has certain inherent advantages in terms of flexibility in controlling the process. Low cold work, better finish, improved surface hardness, enhanced fatigue life, corrosion resistance, improved dimensional control, etc., are some of the all-round benefits that can be obtained from the current apparatus. This technology could be very useful, ranged from common small-scale industries to hi-tech applications, as the tooling and fixturing were developed with a vision to process varieties of materials for versatile applications and the process can be readily accommodated in an existing machine shop environment. The process could be applied to critical components effectively, as it has significant process cycle time advantage, lower capital cost and suitability to adapt existing machine layout and high-speed machining concepts.
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A seminar report onLOW PLASTICITY BURNISHING
OutlineNeed of Surface enhancementWhy LPB?ProcessIt’s BenefitsProcess Design ProtocolAdvantagesApplicationConclusionReferances
Need of Surface enhancement To minimize sensitivity to fatigue
Stress corrosion failure mechanisms
Surface enhancement process• Shot peening• Deep Rolling• Low Plasticity Burnishing (LPB™)• Controlled Plasticity Burnishing• Controlled covrage peening• Laser shock peening
Why should go for LPB?• Surface Treatment Speed Cold work Depth
• Shot Peening Fast High 15-50% ˜0.2 mm
• Gravity Peening Fast Lower 10-20%
˜0.5 mm
• Low Plasticity Burnishing (LPB)
Moderate Low 2-5% ˜1mm ›7+mm
• Deep Rolling Moderate High 10-50% ˜1 mm+
• Laser Shock Peening (LSP)
Slow Low 5-7% ˜1-2 mm
Low Plasticity Burnishing (LPB™)
SchematicLPB™ uses a patented constant volume hydrostatic tool
design to "float" the burnishing ball continuously during operation, regardless of the force applied.
Benefits Fatigue Life Extension Damage Tolerance ImprovementManufacturing DamageStress Corrosion Cracking and
Corrosion FatigueWeight Reduction Material SubstitutionPerformance Improvement
Process
Tool is synchronized with the CNC tool positioning, using either CNC machine tools or industrial robots.
Highly repeatablePrecise reproduction in the manufacturing
environment.Minimize operator interactionProcessing accuracy within 0.1%
Process Design Protocol
Total Engineering SolutionsTurn Key Solution for fatigue & stress corrosion
cracking problems.Step 1: Applied Stresses Step 2: Fatigue Design Step 3: Residual Stress Modeling Step 4: Compression ValidationStep 5: Fatigue Life VerificationStep 6: Processing Tools & CodeStep 7: Statistical Quality ControlStep 8: Turn-Key Production
Finite Element Analysis
Lambda provides the design of the optimal residual stress field and the range of compression allowable in production, along with the necessary tooling for LPB™
processing as part of the non-recurring engineering supporting each
LPB™ application.
Residual Stress
Lambda’s unique combination of residual stress and
cold work measurement, fatigue design, processing and
testing capabilities provide the means to select and design
surface enhancement processes for optimal component
performance.
Effect of LPB on HCF Performance and FOD Tolerance:
HCF Result 38% increase in the endurance limit for LPB (>620 MPa
(>90ksi)) compared to shot peening (~448 MPa (~65 ksi)) after exposure to 425°C (795°F) for 10 hrs.
Increase in the HCF fatigue strength at 2x106 cycles for LPB over shot peening for either 525°C or 600°C exposure for 100 hrs.
The deep compressive layer produced by LPB is more effective in retarding crack growth, even after thermal exposure, because of the minimal thermal stress relaxation and the greater depth of the compressive layer.
Lives superior to that of shot peening even without FOD.
Quality Control Process Monitoring
Advantages and Benefits • Low capitalization costs.• Fewer chances for human error.• No specialized or remote facilities. • 100% QA• LPB™ causes no surface damage.• Applicable to arbitrary shapes and
directions.• A deep compressive layer• There is no possibility of internal
fracture• LPB™ can reduce inspection
requirements, achieving maximum safety at a minimal cost.
• LPB™ has the ability to improve HCF and SCC or mitigate damage
Application Mitigation of Damage Mechanisms Fretting Stress Corrosion Cracking (SCC) Stress Concentrations Corrosion Pitting Foreign Object Damage (FOD) Weld Induced Tension Corrosion Fatigue
Applications by Use and Industry Aircraft Propulsion Aircraft Structures Medical Implants Nuclear/Power Generation
Conclusion From the all study of this , it gives the better
understanding of low plasticity burnishing LPB, and its significance in todays industry.It is most efficient & beneficial suface enhancement process.
Necessary to improve performance & reduce metal fatigue,SCC & corrosion fatigue failures.
Life of component increases.
Referances
Websites:www.lambdatechs.com/html/documents/
Aa_pp.pdfwww.sufaceenhancement.com/techpapers/
729.pdfwww.grc.nasa.govwww.techbriefs.com/index.php?
option=com_staticxt&staticfile=brief/Aug02/LEW17188.html
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