There is no denying that humans love objects that are shimmering. We gather so many objects that have the effect of reflecting the light and give us the shimmering effect we are after. The jewels are certainly the master of reflecting light and give us that mesmerizing effect. To most people's surprise, the mirror is actually a piece of metal too. It has a piece of metal that is so smooth that combines with a glass, we can even see our own reflection. Perhaps the most common example lies in the deep bottom of our pocket, the coins. How many times do we stop and wonder how the coins are made? The component, the detail, the portrait, these are all fascinating traits. But the shimmering surface makes them stand out easily. However, if each time we polish metals to make them shine, it will lose a lot of it. Luckily, we have a tool to help us deal with this situation, the roller burnishing tool.
Roller burnishing is a technique which utilizes very hard and fine-polished steel rollers to be in contact with the softer part of the metal. The pressure contact of the steel rollers can help create a finishing surface. The process goes as the pressure generated by the steel rollers begins to exceed the yield point of the piece-part material. There is a flowing of cold sub-surface material which will deform the surface plastically. The result of such a process is that a surface that is smooth like a mirror is created. This process also manages to polish the surface to a mirror-like state without removing any metal. The surface which is created this way has the ability to handle heavy loading, and the ability is much better than the surface created through the method of abrasive metal removal.
According to the profilometer reading, one of the advantages of the roller burnished surface is that the surface which is created this way is much smoother and a lot more wear-resistant than the surface of an abraded surface. Profilometer is a type of measuring instrument, whose main purpose is to measure the roughness of the surface. In the process of abrasive finishing, metal is removed through cutting or tearing. The result of such a process is that the roughness of the profile is low, and sharp projections will be left in the contact plane of the machined surface. Unlike the abrasive finishing method, roller burnishing will dislocate the metal instead of removing it. There is also another factor to consider, every time we try to machine a metal surface, it will leave microscopic peaks and valleys that are called roughness. It is our top priority to reduce the roughness average (RA)value of the surface. People use the RA value to measure the distance and the bottom of the points. If the valley is shallow and the peak is short, this denotes that the surface is smooth.
As I mentioned earlier, the cold-flow effect of the rotary tool will apply the rollers to the surface completely, and in turn causing the peaks to flow into the valleys and the valleys to flow in the upward direction toward the peaks. Besides, the cold flowing is capable of stimulating the material at both the peaks and a thousand of an inch down beneath the surface. It will flow them together, and the process will create a plateau-like profile that possesses the contact plane which is much less sharp than the one created through abrasion. Due to the fact that the finish comes from subsurface effects, a burnished surface has the advantage of both smooth hand work-hardened when it comes to better durability. However, not all types of materials are suitable to use the roller burnishing method. The roller burnishing method works best when the material is soft. The metals which are very ductile and malleable such as steel, aluminum, and copper are very suitable for the roller burnishing method. The hardness which is best recommended for roller burnishing is not higher than 40 HRC. As for the roughness, it is agreeable for the roller burnishing method to have a surface with an initial of roughly 80 microinches to 120 microinches for a start.
There are several types of roller burnishing tools, each is with its own distinctive traits. For example, the Roll-a-Finish tool has the ability to adjust its tool diameter in order to achieve the desired surface finish. Other types of roller burnishing tools like the universal burnishing tool and the diamond burnishing tool all got their specialties. But they have one thing in common, they can all make the surface very smooth without tearing any of it down.
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