OBRABOTKAMETALLOV Vol. 26 No. 3 2024 technology Modeling and optimization of roller burnishing of Al6061-T6 process for minimum surface roughness, better microhardness and roundness Rashmi Dwivedi 1, a, Avinash Somatkar 1, 2, b, Satish Chinchanikar 2, c,* 1 Mechanical Engineering Department, Sri Satya Sai University of Technology & Medical Science, Sehore, Madhya Pradesh, 466001, India 2 Department of Mechanical Engineering, Vishwakarma Institute of Information Technology, Pune, 411048, India a https://orcid.org/0000-0002-9755-5330, rashmidwivedi29@gmail.com; b https://orcid.org/0000-0002-2885-2104, avinash.somatkar@viit.ac.in; c https://orcid.org/0000-0002-4175-3098, satish.chinchanikar@viit.ac.in Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2024 vol. 26 no. 3 pp. 52–65 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2024-26.3-52-65 ART I CLE I NFO Article history: Received: 09 June 2024 Revised: 17 June 2024 Accepted: 22 June 2024 Available online: 15 September 2024 Keywords: Roller burnishing Al6061-T6 Surface roughness Microhardness Roundness Optimization ABSTRACT Introduction. Roller burnishing is one of the most common methods of improving the surface quality of parts, wear resistance, microhardness, and corrosion resistance. The process involves compressing and smoothing the workpiece using the pressure of a hardened roller. It is often used to improve part performance and lifespan in sectors including automotive, aerospace, and medical equipment manufacturing. The literature reviewed shows that the roller burnishing process effectively improves the overall surface quality and hardness of the workpiece. In addition, roller burnishing is considered as an affordable method to enhance the functionality and robustness of machined parts by reducing the likelihood of surface defects such as like scratches and cracks. However, very few studies have been reported on the modeling and optimization of roller burnishing of Al6061-T6 for minimum surface roughness, better microhardness, and roundness. The methods of investigation. In the current work, roller burnishing of Al6061-T6 is modeled and optimized for superior microhardness, roundness, and minimal surface roughness. Under dry-cutting conditions, the performance of roller burnishing of Al6061 specimens is assessed in terms of process factors such as cutting speed, feed, and number of passes. Mathematical models to predict the surface roughness, microhardness, and deviation in roundness are developed based on the experimental results. Results and Discussion. The coefficient of correlation for the developed models is found to be close to 0.9, which indicates that it can be reliably used to predict and optimize the roller burnishing of the Al6061-T6. According to this study, the use of the following cutting parameters leads to the lowest variation in roundness (4.282 µm), the better microhardness (119.2 Hv), and the lowest surface roughness (0.802 µm): cutting speed 344 rpm, feed 0.25 mm/rpm and four passes. Further, the study reveals that increasing the number of passes (beyond four) does not significantly improve the surface roughness or microhardness. However, it does lead to a slight increase in the roundness deviation. Therefore, in order to achieve optimal results, it is recommended to use a maximum of four passes during roller burnishing of Al6061 specimens under dry cutting conditions. These results imply that roller burnishing can effectively improve the overall quality and hardness of the workpiece surface. In addition, roller burnishing is considered as an affordable method to increase the functionality and robustness of machined parts by reducing the likelihood of surface defects like scratches and cracks. For citation: Dwivedi R., Somatkar A., Chinchanikar S. Modeling and optimization of roller burnishing of Al6061-T6 process for minimum surface roughness, better microhardness and roundness. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2024, vol. 26, no. 3, pp. 52–65. DOI: 10.17212/1994-6309-2024-26.3-52-65. (In Russian). ______ * Corresponding author Satish Chinchanikar, D.Sc. (Engineering), Professor Vishwakarma Institute of Information Technology, 411048, Pune, India Tel.: +91-2026950401, e-mail: satish.chinchanikar@viit.ac.in Introduction The surface quality of parts created by various metal forming and machining processes is improved using traditional chip removal techniques like grinding, lapping, and shaving. However, research is still being conducted to find new ways to produce parts in a single process and find new ways to produce parts in one process and eliminate secondary finishing procedures. This is because higher finishing quality standards, lower production costs and shorter production times improve competitiveness. One of the most widely used techniques is the burnishing procedure, which is carried out on a variety of metal workpieces using roller and ball forms. Burnishing is a process that smooths out surface defects on a
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