Finite element analysis and design optimization of low plasticity burnishing process

In the present study, Low Plasticity Burnishing (LPB®) process on the half-space specimen has been simulated using a 3D explicit nonlinear finite element model. The developed finite element model is then used to investigate the effect of main parameters including ball diameter, burnishing force, burnishing feed, and number of passes on the resultant profile of residual stress and plastic deformation. Due to high computational cost associated with the nonlinear finite element model and in order to practically conduct design optimization of the LPB process, the design of experiment combined with the response surface methodology has been used to develop smooth response functions to efficiently and accurately approximate the residual stress profile and plastic deformation over the entire design space. Finally in order to improve the LPB process, a design optimization using the developed response functions has been formulated to obtain the optimum set of parameters such that a deep residual compressive stress with small plastic deformation is generated throughout the thickness of component.