Experimental Analysis of Ballizing Process Effects on the Surface Integrity and Dynamic Behavior of Rotating Machined Components
Keywords:
Ballizing process, Surface integrity, Vibration analysis, Rotating machined components, Process optimizationAbstract
The ballizing process is a mechanical surface enhancement technique widely employed to improve the surface integrity and functional performance of machined components through controlled plastic deformation. This experimental study investigates the effects of ballizing process parameters on the surface integrity and dynamic behavior of rotating machined components. Key parameters, including ballizing force, feed rate, ball diameter, rotational speed, and lubrication conditions, were systematically varied using a Taguchi L25 orthogonal array to ensure comprehensive coverage of operating conditions. Surface integrity was evaluated in terms of surface roughness, microhardness, and residual stress characteristics, while dynamic behavior was assessed through vibration measurements in horizontal, vertical, and axial directions. Signal-to-Noise ratio analysis and Analysis of Variance were employed to identify optimal parameter combinations and determine the statistical significance of individual factors. The experimental results reveal that optimized ballizing conditions lead to notable reductions in surface roughness and vibration amplitudes, along with improved surface hardness and compressive residual stress formation. A strong correlation between enhanced surface integrity and reduced vibrational response was observed, highlighting the role of ballizing in improving dynamic stability and operational reliability of rotating components. The findings demonstrate that ballizing serves not only as an effective surface finishing process but also as a critical technique for vibration control in rotating machinery. This study provides practical insights for process optimization and supports the integration of ballizing in high-performance manufacturing applications.
References
Malarvizhi, S., Chaudhari, A., Woon, K. S., Kumar, A. S., & Rahman, M. (2016). Influence of burnishing axial interference on hole surface quality in deep hole drilling of Inconel 718. Procedia Manufacturing, 5, 1295-1307.
Mamros, E. M., & Nikhare, C. P. (2018, September). Experimental investigation on tube flaring with a rotating tool. In IOP Conference Series: Materials Science and Engineering (Vol. 418, No. 1, p. 012118). IOP Publishing.
Maximov, J. T., Duncheva, G. V., & Amudjev, I. M. (2013). A novel method and tool which enhance the fatigue life of structural components with fastener holes. Engineering Failure Analysis, 31, 132-143.
Maximov, J. T., Duncheva, G. V., Anchev, A. P., & Amudjev, I. M. (2019). New method and tool for increasing fatigue life of a large number of small fastener holes in 2024-T3 Al alloy. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 41(4), 203.
Milenin, A., Kustra, P., Byrska-Wójcik, D., & Furushima, T. (2017). Physical and numerical modelling of laser dieless drawing process of tubes from magnesium alloy. Procedia Engineering, 207, 2352-2357.
Milenin, A., Kustra, P., Furushima, T., Du, P., & Němeček, J. (2018). Design of the laser dieless drawing process of tubes from magnesium alloy using FEM model. Journal of Materials Processing Technology, 262, 65-74.
Mohamed, F. A., El-Abden, S. Z., & Abdel-Rahman, M. (2005). A rotary flange forming process on the lathe using a ball-shaped tool. Journal of Materials Processing Technology, 170(3), 501-508.
Morimoto, T., & Tamamura, K. (2023). Burnishing process using a rotating ball-tool: Effect of tool material on the burnishing process. Wear.
Morsiya, C. V., & Pandya, S. N. (2022). Recent advancements in hybrid investment casting process—a review. Recent Advances in Manufacturing Processes and Systems: Select Proceedings of RAM 2021, 817-831.
Naidu, N. R., & Raman, S. G. S. (2005). Quality improvement using Taguchi method in shot blasting process. Journal of Mechanical Engineering and Sciences, 10(2), 2200-2213.
Parsa, M. H., & Nasher Al Ahkami, S. (2008). Bending of work hardening sheet metals subjected to tension. International Journal of Material Forming, 1(Suppl 1), 173-176.
Pater, Z., Gontarz, A., & Tofil, A. (2011). Analysis of the cross-wedge rolling process of toothed shafts made from 2618 aluminium alloy. Journal of Shanghai Jiaotong University (Science), 16(2), 162-166.
Pater, Z., Kazanecki, J., & Bartnicki, J. (2006). Three dimensional thermo-mechanical simulation of the tube forming process in Diescher's mill. Journal of Materials Processing Technology, 177(1-3), 167-170.
Downloads
How to Cite
Issue
Section
License
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
