2D FEM Investigation of Residual Stress in Diamond Burnishing

Sliding friction diamond burnishing is a finishing machining operation whose purpose is to improve the surface integrity of previously machined surfaces and increase their surface hardness. When analyzing a complex process involving plastic deformation, friction, and the interaction between solids, finite element models (FEMs) involve a significant amount of simplification. The aim of this study is to investigate a 2D FEM of the residual stress occurring during diamond burnishing. Before burnishing, the samples were processed by fine turning. Based on the simulations and laboratory experiments performed, it can be concluded that the diamond burnishing process can be modeled with relatively good approximation using two-dimensional modeling. It was also concluded that it is important to consider the initial surface topography in two-dimensional tests. The results indicate that the diamond burnishing process improved the residual stress properties of EN 1.4301 austenitic stainless steel by creating relatively high compressive stress, whose magnitude was between 629 and 1138 MPa depending on the applied force. However, the stress distribution is not uniform; it is mostly concentrated under the roughness peaks.