Analytical modeling of ultrasonic surface burnishing process: Evaluation of residual stress field distribution and strip deflection

Ultrasonic surface burnishing (USB) process is a promising surface enhancement technique that improves fatigue life of components by exerting work hardening and compressive residual stress of the surface layers. However, USB is a complex process in practice, and there is not an analytical model published to facilitate the design and comprehension of the process. In the present paper an analytical elastic-plastic model was developed to correlate USB process factors to residual stress field (RSF). Also, deformation of strip samples was determined in the analytical approach. Parameters such static force, ultrasonic vibration amplitude, ball material and its diameter as well as ultrasonic vibration frequency were included in the model to find how they influence the residual stress variation and strip deflection. Two types of material constitutive equation i.e. Johnson-Cook (JC) that is sensitive to strain rate as well as Chaboche hardening that is influenced by cyclic loading were considered to find which material behavior is more consistent with experimental results. The experiments have been carried out on two different materials with various initial state of residual stress field (IRSF). It was obtained from the results that residual stress field variation and strip deflection obtained by experiments are consistent well with the values derived from analytical model. Therefore, the model was comprehensively used to find how the USB process factors influence the RSF and strip deflection.