Burnishing Process Using Spherical 5-DOF Hybrid-Type Parallel Mechanism with Force Control
Masato Okada, Hiroaki Kozuka, Hiroshi Tachiya,
Taira Iwasaki, and Yorihiro Yamashita
Faculty of Mechanical Engineering, Institute of Science and Engineering, Kanazawa University, Kakuma-machi, Kanazawa, Ishikawa 920-1192, Japan
This paper proposes a novel diamond tip burnishing process to improve the integrity of various free-curved surfaces using a spherical 5-Degree-Of-Freedom (5-DOF), hybrid parallelmechanism. The developed parallel mechanism, which has high rigidity and a large workspace, is composed of a spherical 3-DOF parallel mechanism and an XY stage, and is equipped with a burnishing tool on its output link. Using a threedimensional force control system, the parallel mechanism can adjust the thrust force in the burnishing process. The surface roughness and profile of the stainless steel (AISI 316) workpiece, burnished by the proposed method, were evaluated. The surface integrity depended on the values of cross-feed and thrust force, which were controlled by the hybrid parallel mechanism. In addition, the surface roughness improved as cross-feed decreased and thrust force increased. The preliminary surface roughness of Ra = 2.5 µm was improved to Ra = 0.25 µm in the burnishing process of the free curved surface, and homogeneous surface integrity was obtained. The results thus suggest that the proposed burnishing method can achieve a highquality surface finish, even on a free curved surface.
-  K. Konefal, M. Korzynski, Z. Byczkowska, and K. Korzynska, “Improved corrosion resistance of stainless steel X6CrNiMoTi17-12-2 by slide diamond burnishing,” J. Materials Processing Technology, Vol.213, No.11, pp. 1997-2004, 2013.
-  H. Luo, J. Liu, L. Wang, and Q. Zhong, “Study of the mechanism of the burnishing process with cylindrical polycrystalline diamond tools,” J. Materials Processing Technology, Vol.180, No.1-3, pp. 9-16, 2006.
-  M. Korzynski, J. Lubas, S. Swirad, and K. Dudek, “Surface layer characteristics due to slide diamond burnishing with a cylindricalended tool,” J. Materials Processing Technology, Vol.211, No.1, pp. 84-94, 2011.
-  A. Sagbas, “Analysis and optimization of surface roughness in the ball burnishing process using response surface methodology and desirabilty function,” Advances in Engineering Software, Vol.42, No.11, pp. 992-998, 2011.
-  F. L. Li, W. Xia, Z. Y. Zhou, J. Zhao, and Z. Q. Tang, “Analytical prediction and experimental verification of surface roughness during the burnishing process,” Int. J.Machine Tools and Manufacture, Vol.62, pp. 67-75, 2012.
-  M. Korzunski, J. Lubas, S. Swirad, and K. Dudek, “Surface layer characteristics due to slide diamond burnishing with a cylindricalended tool,” J. Materials Processing Technology, Vol.211, No.1, pp. 84-94, 2011.
-  H. Tanaka, K. Nishinaka, and K. Yanagi, “Development of hydraulic burnishing tool for discontinuous surface finishing: Machining characteristics of hydrostatic burnishing tool with single crystal diamond tip,” J. the JSTP, Vol.53, No.621, pp. 924-928, 2012. (in Japanese)
-  S. Ibaraki, T. Yokawa, A.Matsubara, Y. Kakino, M. Nakagawa, and T. Matsushita, “A Study on the Improvement of Motion Accuracy of Hexapod-type Parallel Mechanism Machine Tools (3rd Report) : A Kinematic Calibration Method Considering Gravity-induced Errors,” J. the JSPE, Vol.72, No.3, pp. 355-359, 2006. (in Japanese)
-  T. Oiwa, “Precision Mechanisms Based on Parallel Kinematics,” Int. J. Automation Technology, Vol.4, No.4, pp. 326-337, 2010.
-  H. Yachi and H. Tachiya, “Calibration Method for a Parallel Mechanism Type Machine Tool by Response Surface Methodology – Consideration via Simulation on a Stewart Platform Mechanism –,” Int. J. Automation Technology, Vol.4, No.4, pp. 355-363, 2010.
-  H. Tachiya, Y. Yamamoto, N. Hashimoto, and Y. Kaneko, “Evaluation of Output Errors of Multiple Degree-of-Freedom Mechanisms to the Forces in Arbitrary Direction – Proposal of an Evaluation Method and Improvement of Rigidity of a Spatial 3-dof Parallel Mechanism –,” Trans. of the Japan Society of Mechanical Engineers, Series C, Vol.71, No.701, pp. 214-220, 2005. (in Japanese)
-  H. Yachi, H. Tachiya, T. Umi, and R. Hattori, “Tool Path Generation for a Parallel Mechanism Machine Tool by Predicting Its Output Motion,” Trans. of the Japan Society of Mechanical Engineers, Series C, Vol.75, No.752, pp. 1114-1121, 2009. (in Japanese)
-  H. Tachiya, Y. Aoki, H. Yachi, and M. Takeda, “Calibration of Parallel Mechanisms for Machine Tools Using Response Surface Methodology,” Trans. of the Japan Society of Mechanical Engineers, Series C, Vol.76, No.767, pp. 1870-1877, 2010. (in Japanese)
-  J. J. Craig, “Introduction to Robotics: Mechanics and Control (3rd Ed.),” Prentice Hall, ISBN-10:0201543613, 2004.
-  H. Seraji, D. Lim, and R. Steele, “Experiments in Contact Control,” J. Robotic Systems, Vol.13, No.2, pp. 53-73, 1996.
-  Z.-X. Peng and N. Adachi, “Position and Force Control of Manipulators without Using Force Sensors,” JSME Int. J. Ser. III Vibration, Control Engineering, Engineering for Industry, Vol.35, No.2, pp. 252-258, 1992.
-  H. Arai, “Robotic Metal Spinning – Shear Spinning Using Force Feedback Control –,” J. the Robotics Society of Japan, Vol.22, No.6, pp. 798-805, 2003. (in Japanese)
-  K. Kosuge, K. Takeo, D. Taguchi, T. Fukuda, and H. Murakami, “Task-Oriented Force Control of Parallel Link Robot for the Assembly of Segments of a Shield Tunnel Excavation System,” IEEE/ASME Trans. on Mechatronics, Vol.1, No.3, pp. 250-258, 1996.
-  M. Korzynski, “Modeling and experimental validation of the forcesurface roughness relation for smoothing burnishing with a spherical tool,” Int. J. Machine Tools and Manufacture, Vol.47, No.12-13, pp. 1956-1964, 2007.
-  X. Yu and L. Wang, “Effect of various parameters on the surface roughness of an aluminium alloy burnished with a spherical surfaced polycrystalline diamond tool,” Int. J.Machine Tools andManufacture, Vol.39, No.3, pp. 459-469, 1999.
-  H. Tanaka, H. Tabuto, K. Yanagi, andM. Futamura, “Effect of surface hardened steel texture of preliminary process on burnishing process – A metrological study of hardened steel surface finishing using diamond burnishing tool –,” J. the JSTP, Vol.50, No.581, pp. 555-559, 2009. (in Japanese)