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<p>The application of ultrasonic waves in ball burnishing enhances the surface properties of components. This study proposes a novel and integrated framework for enhancing the work-hardening behavior of AISI 1045 steel using ultrasonic-assisted ball burnishing (UB). Whereas previous research primarily addressed surface integrity indicators, this work centers on tensile-based evaluation of work-hardening behavior. It employs tensile test data to optimize results, with a particular focus on the UB process, and systematically investigates the influence of key process parameters—feed rate, number of passes, and processing type (UB vs. conventional ball burnishing, CB)—on mechanical response. A key contribution of this study is the integrated use of tensile-based analysis, optimization with the aid of genetic algorithms (GA), and finite element method (FEM) simulation to investigate work-hardening behavior in UB. The experimental methodology integrates tensile testing, surface characterization, hardness profiling, and microstructural analysis, supported by FEM simulations in ABAQUS to predict subsurface responses such as compressive residual stress (CRS) and equivalent plastic strain (PEEQ). The GA optimization identified an optimal combination of parameters—low feed rate, high number of passes, and UB processing—that led to significantly improved performance: increased UTS, reduced elongation, and improved surface roughness. The UB process also induced micro-dimpled surface textures and deeper plastic deformation zones, contributing to more effective subsurface work hardening. The lowest work-hardening exponents observed in UB-treated specimens indicate greater strengthening efficiency compared to CB. FEM results confirmed substantial subsurface improvements, with CRS values approximately –650&#xa0;<InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\text{MPa}\)</EquationSource> <EquationSource Format="MATHML"><math> <mtext>MPa</mtext> </math></EquationSource> </InlineEquation> and PEEQ around 0.25, in close agreement with experimental stress–strain curves.</p>

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An investigation of ultrasonic-assisted ball burnishing process: surface properties and work-hardening behavior of AISI 1045 steel

  • 期刊论文

  • 发表日期：

    2025年10月3日

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  • Alireza Bagheri Bami,
  • Saeid Amini,
  • Atefeh Ghaed Amini

摘要

The application of ultrasonic waves in ball burnishing enhances the surface properties of components. This study proposes a novel and integrated framework for enhancing the work-hardening behavior of AISI 1045 steel using ultrasonic-assisted ball burnishing (UB). Whereas previous research primarily addressed surface integrity indicators, this work centers on tensile-based evaluation of work-hardening behavior. It employs tensile test data to optimize results, with a particular focus on the UB process, and systematically investigates the influence of key process parameters—feed rate, number of passes, and processing type (UB vs. conventional ball burnishing, CB)—on mechanical response. A key contribution of this study is the integrated use of tensile-based analysis, optimization with the aid of genetic algorithms (GA), and finite element method (FEM) simulation to investigate work-hardening behavior in UB. The experimental methodology integrates tensile testing, surface characterization, hardness profiling, and microstructural analysis, supported by FEM simulations in ABAQUS to predict subsurface responses such as compressive residual stress (CRS) and equivalent plastic strain (PEEQ). The GA optimization identified an optimal combination of parameters—low feed rate, high number of passes, and UB processing—that led to significantly improved performance: increased UTS, reduced elongation, and improved surface roughness. The UB process also induced micro-dimpled surface textures and deeper plastic deformation zones, contributing to more effective subsurface work hardening. The lowest work-hardening exponents observed in UB-treated specimens indicate greater strengthening efficiency compared to CB. FEM results confirmed substantial subsurface improvements, with CRS values approximately –650  \(\text{MPa}\) MPa and PEEQ around 0.25, in close agreement with experimental stress–strain curves.