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ICTMES 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1189 (2021) 012002 doi:10.1088/1757-899X/1189/1/012002

Impact of Ball Burnishing Process on Residual stress

distribution in Aluminium 2024 Alloy using Experimental
and Numerical Simulation

Harish1, D. Shivalingappa1, Raghavendra.N1, Ganesh V2

1
Department of Mechanical Engineering, B. N. M. Institute of Technology, Bengaluru 560070, India.
2
Research Engineer , Fracktal Works Pvt.Ltd

Abstract: Deep ball burnishing is surface enhancement process is specifically used to induce
compressive residual stress in material sub surface. In this investigation deep ball burnishing
surface treatment process was carried out on the periphery of Al 2024 alloy and induced
beneficial compressive residual stress was determined by X-Ray Diffraction method. In this
work explicit module of the FE-Code ABAQUS-6.17 was used to model the ball burnishing
process and analysis is carried out to determine the residual stresses in Aluminium 2024 Alloy
by changing instantaneously process variables like burnishing passes and pressure. Comparison
was made among experimental and results obtained from FEA, it was observed that there is well
agreement between the FE Results and experimental results. Also the results revealed the impact
of deep ball burnishing process parameters on distribution of beneficial compressive residual
stress.
Keywords : Ball burnishing, Residual stress, Finite element analysis.

1. Introduction
The cyclic loads are the prime reason for failure of aero engine components. The aeroengine parts
manufactured mainly fails due to the cyclic loads as they are instantaneously subjected to HCF and
LCF. Lack of mirror surface finish of the part would increase the rate of crack initiation, propagation
and gradually leads to the failure of component. In commercial practice many surface coating and
surface treatment processes are available to enhance surface integrity properties of engineering
components like laser shock peening, deep rolling, Burnishing which helps to avoid the fatigue failure
of engine components. Aviles R et al.[1] investigated the effect of deep ball burnishing on fatigue life
of mechanical components with and without surface treatment. In this work deep ball burnishing surface
treatment is employed to improve the surface integrity parameters that are needed to enhance its fatigue
life. Rolling process makes the component surface smoother with out producing chip and with less
amount of cold work. The integral process rolling variables like pressure, force, speed, feed, types of
lubricant also affects the treatment effectiveness. Loh N[2] conducted exhaustive literature work related
to the process variable parameters affecting the surface integrity of components in turn increase the
fatigue life. Harish et al.[3] conducted the comparative study of influence of deep ball and roller
burnishing treatment on surface integral properties mainly its impact on induced residual stresses of
Aluminium 2024 Alloy. It was found that ball burnishing process was effective in improving the
hardness while roller burnishing process was effective in surface roughness. Beres et al.[4] numerically
investigated the residual stress distribution results of low plasticity burnishing process. Harish et al
[5]analysed the impact of ball burnishing on surface properties of Aluminium 2024 Alloy. It was found
that ball burnishing process has a great impact on the surface enhancement of material.

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
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ICTMES 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1189 (2021) 012002 doi:10.1088/1757-899X/1189/1/012002

2. Selection of Test Specimen

In this investigation the deep burnishing process is carried out on Aluminium alloy 2024. Al 2024 alloy
is an most widely used element in aero engine component manufacturing industry due to its resistance
to fatigue failure and its valuable strength to weight ratio. The main constituent of Al 2024 alloy is Cu
(4.95%).Ultimate tensile strength and yield strength was found to be 469 Mpa , 441 Mpa respectively.
Details of Material properties of Al 2024 alloy was given in below Table 1.
Elements Al Cu Cr Mg Mn Si
(Wt %) 94.7 4.9 0.1 1.8 0.9 0.5
Table1 Material properties used for simulating Aluminium 2024 Alloy
3. Experimentation `
The deep rolling burnished tool consists of tungsten carbide steel ball, helical spring, hydrostatic bearing
seat. The steel ball is pressed against the specimen with hydraulic pressure supplied by hydraulic unit
of pressure of maximum capacity 20MPa.The deep rolling tool is fixed in the tool post of conventional
lathe machine. Seven equal spaces were machined on the specimen. Later Specimen was placed in
between supporting chucks of lathe. Then with the help of burnishing tool, ball is pressed over
specimen. Deep rolling process was carried out at different section by varying overturns and pressure
to understand the effectiveness of burnishing treatment. Burnishing Process is carried out under the
different pressure at different sections. In this investigation treatment is carried out using the variable
pressure 10MPa, 15MPa and 20MPa respectively. The maximum overturns carried out at specimen
surface is 3. After the completion of surface treatment the beneficial compressive stress is measured by
X-Ray diffraction method.

Figure 1 Deep Ball Burnishing process

4. Finite Element Modelling

The ABAQUS 6.17 is used to simulate burnishing process to investigate residual stresses in various
depth. The numerical simulation was carried out using two variables i.e burnishing pass and burnishing
pressure. The 3D finite element mesh for modelling of the deep ball burnishing process as shown in
figure below. The simulation has been carried out by assuming tungsten carbide ball as a rigid and
rectangular Al 2024 alloy as deformable. In this analysis the used boundary conditions are rotation and
linear displacement for rigid ball and plate is completely constrained in all the directions. In this
analysis work piece was meshed using C3D8R elements. Figure 2 shows the meshing strategy of the
rectangular specimen. The burnishing process is followed as according to the burnishing pattern.

2
ICTMES 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1189 (2021) 012002 doi:10.1088/1757-899X/1189/1/012002

Figure 2 3D finite element mesh for modelling of the Deep Ball Burnishing process.

5. Numerical Results and its Validation.

After the numerical simulation of deep rolling process, induced residual stresses in longitudinal and
transverse direction as shown in below figure 3 and 4. Longitudinal and transverse residual stresses are
computed by varying process parameters such as overturns and deep rolling pressure are shown in the
figure 6,7 and 8.The experimental results obtained in [3] is validated with numerical simulation results.
It was observed that experimental results are deviating by numerical results only by 9%

Figure 3 Longitudinal residual stress distribution

Figure 4 Transverse residual stress distribution

3
ICTMES 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1189 (2021) 012002 doi:10.1088/1757-899X/1189/1/012002

Validation of results:
The experimental results obtained in [3] is validated with numerical simulation results. It was observed
that experimental results are deviating by numerical results only by 9%. To verify the accuracy of the
numerical simulation of ball burnishing process, the residual stress profile comparison made and it is
shown in figure 5.The stress distribution for the rolling variables in longitudinal direction was shown
in figures 6, 7, 8 and 9.

-50
Longitudinal Residual stress(MPa)

-100

-150

-200

FEM Solution
-250 Experimental Result

-300
0.0 0.2 0.4 0.6 0.8 1.0
Depth(mm)

Figure 5 validation of results

50 50
Longitudinal Residual stress(MPa)

Longitudinal Residual stress(MPa)

0 0

-50
-50

-100
-100
-150
1st pass
-150 1st pass
2nd pass -200
2nd pass
-200 3rd pass 3rd pass
-250

-250 -300

0.0 0.5 1.0 1.5 2.0 2.5

0 . 0 0 . 5 1 . 0 1 . 5 2 . 0 2 . 5

Depth (mm)
Fig.6 stress distribution for pressure 10 MPa Fig. 7 stress distribution for pressure 15 MPa

4
ICTMES 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1189 (2021) 012002 doi:10.1088/1757-899X/1189/1/012002

100 50

Longitudinal Residual stress(MPa)

Longitudinal Residual stress(MPa)

0
-50

-100 -100

-150

-200
-200
1st pass
2nd pass -250
-300
3rd pass Pressure 15MPa
-300 Pressure 20MPa
Pressure 25MPa
-400
-350

0.0 0.5 1.0 1.5 2.0 2.5 0.0 0.5 1.0 1.5 2.0 2.5

Depth (mm) Depth(mm)

Figure 8 Residual stress distribution for 3rd pass Figure 9 Residual stress distribution for varied pressure.

6. Conclusion :
A comprehensive 3D finite explicit dynamic analysis was conducted to simulate the ball burnishing
process .Based on obtained residual stress distribution from FE method and experimental method the
following conclusions are drawn.
• It was found that experimental results shows well agreement with the numerical results. The
results revealed that increase in overlap of the rolling tracks largely increases the magnitude of
the residual stress created in target plate.
• Numerical results revealed that the overlapping effect has a greater impact on residual stress
distribution in the given material.
• It is also found that burnishing passes also major impact on the residual stress distribution in
Aluminium 2024 Alloy.
• It may also be observed that the depth of residual stress was improved by increasing the
burnishing pressure.
References
[1] R. Avilés, J. Albizuri, A. Rodríguez, and L. N. López de Lacalle, “On the fatigue strength of ball
burnished mechanical elements,” Mechanisms and Machine Science, vol. 17, pp. 365–373, 2014, doi:
10.1007/978-94-007-7485-8_45.

[2] N. H. Loh and S. C. Tam, “Effects of ball burnishing parameters on surface finish A literature survey
and discussion,” 1988.

[3] Harish and D. Shivalingappa, “The influence of ball and roller burnishing process parameters on surface
integrity of Al 2024 alloy,” Materials Today: Proceedings, vol. 27, pp. 1337–1340, 2020, doi:
10.1016/j.matpr.2020.02.614.

[4] W. Beres, J. Li, and P. Patnaik, “GT2004-53925 NUMERICAL SIMULATION OF THE LOW
PLASTICITY BURNISHING PROCESS FOR FATIGUE PROPERTY ENHANCEMENT,” 2004.
[Online]. Available: http://www.asme.org/about-asme/terms-of-use.

[5] Harish, D. Shivalingappa, P. Vishnu, and Sampath Kumaran, “Impact of Ball burnishing process
parameters on surface Integrity of an Aluminium 2024 Alloy,” in IOP Conference Series: Materials
Science and Engineering, Jun. 2018, vol. 376, no. 1, doi: 10.1088/1757-899X/376/1/012099.