Mechanical Surface Modification Using Cutting Inserts

Author:  Segebade E., Klose J., Gerstenmeyer M., Zanger F., Schulze V.
Source:  ICSP-13
Doc ID:  2017071
Year of Publication:  2017
Abstract:  
Introduction: Mechanical surface modification processes are applied to create highly functional workpiece surface layer states. The possible surface layer states may render superb resistance against wear and fretting,which can hardly be ensured with the same material by other manufacturing processes. A wide range of different mechanical surface modification processes exist [1]. These are generally sorted by tool type and tool contact situation. The two main groups are those with guided and those with unguided tools. The processes using guided tools are separated in those with continuous and those with periodic contacts. In this work, a new process is presented with a guided tool and periodic contact. Similar processes will be the focus of the following brief technological description. Mechanical surface modification processes with guided tools and periodic contacts are part of the group of processes denominated “Machine Hammer Peening” (MHP) [1]. Hammer peening processes use a ball- or pin-shaped tool to apply plastic deformation to the surface layer of the workpiece, thus changing surface layer states to increase workpiece performance [1]. MHP-processes with periodic contacts are realized with different commercially available systems. These systems can be classified by their force generating system. Pneumatic processes (P-MHP) use pneumatics to generate the necessary impulse for mechanical surface modification [2]. Sonotrode and direct sonotrode driven systems are the most numerous in type [1]. One example is the Ultrasonic Impact Treatment (UIT)devolved by [3], which can be both, sonotrode and direct sonotrode driven [1]. Electromagnetic Machine Hammer Peening (MHP) uses the Lorenz force induced by a fluctuating electrical current to create the necessary kinematic and associated forces [4]. The relatively new Piezopeening [5] offers high flexibility of process parameters (within limits regarding hammer frequency and stroke)through piezoelectric actuators. The resulting beneficial surface layer states include the surface roughness [6], work hardening of the surface layer [7], and induction of compressive residual stresses [8]. Currently most methods for mechanical surface modification like burnishing or machine hammer peening (MHP) of high performance components entail an additional step for the process chain. While there are a number of attempts to shorten process times through hybrid processes (like [9] [10]), a true integration of surface modification into machining operations has not been attempted yet.