Modeling and optimization of roller burnishing of Al6061-T6 process for minimum surface roughness, better microhardness and roundness

OBRABOTKAMETALLOV technology Vol. 26 No. 3 2024 metal, enhancing its shine and durability, and is commonly used in industries such as automotive, aerospace, and jewelry manufacturing. The burnishing procedure improves the surface quality of the workpiece quality on a microscopic level without causing chipping. This is a typical finishing technique used on milling or lathe machines to improve surface quality, wear resistance, microhardness, and corrosion resistance [1]. As a result, it is essential to achieve a high level of surface quality after burnishing [2]. When combined with machine feed, the polishing stress exceeding the yield strength distorts the microscale peaks of the surface and fills the valleys along the polished length [3–4]. Polished materials acquire a more defined external shape due to plastic deformation, which is facilitated by the continuous action of the polishing tool on the surface of the workpiece. It has been laid out that the force applied to the workpiece and the number of passes made during the polishing operation are directly related to the hardness of the workpiece. This strategy is usually performed without the use of any lubricants. Various polishing process parameters, including the kind of polishing interaction, number of passes, the speed and the polishing depth have been the subject of various studies [5–6]. By combining the roller burnishing and electrochemical turning processes, Ebeid and Ei-Taweel [7] investigated surface harshness and material removal rate enhancement in machining Al-Zn-Mg alloy. The information boundaries were examined, utilizing the Taguchi strategy to decide the best qualities. Luo et al. [8] investigated the effects of feed, speed, and entry depth of penetration on the forming power in a machine on metal H62 and Al-composite LY12 utilizing a polycrystalline precious stone device. The results showed that the polishing force was most impacted by factors like depth of penetration, feed, and speed. One of the advancements in the burnishing is the simultaneous utilization of rolling and sliding motions to improve the surface nature of round and hollow metal workpieces made of ASTM 2017 and ASTM 1055. The effects of depth of penetration, feed, and speed on this strategy were also different for different workpiece materials [9]. Roller polishing was used by Sundararajan and Nagarajan [10] to improve the surface qualities of the steel EN8 workpiece. The burnishing was carried out at shaft speeds ranging from 100 to 2,700 rpm and at a constant feed rate. The analysis of the surface roughness and hardness of steel C40E during the burnishing was evaluated by Kumar et al. [11]. The burnishing parameters were speed, feed, entry depth of penetration, and number of passes. Przybylski [12] performed machining, followed by burnishing. His study showed that performing burnishing immediately after machining on the same machine reduces assembly time and eliminates additional finishing operations. Shirsat et al. [13] investigated the parametric effect of force, speed, feed, workpiece width, and ball dimensions on the surface of a metal material after burnishing. The SAE 20, 30, 40, and SAE 50 oils were utilized in the study. Their study showed that using SAE 30 oil provided the best surface quality and the force applied to the workpiece during burnishing had the greatest effect on the finished surface compared to other process parameters considered in the study. In a roller burnishing cycle for a TA2 workpiece, Yuan et al. [14] presented an original technique for selecting the ideal polishing boundaries, such as speed, feed, and entry depth of penetration. The boundaries obtained as a result of the modelling reflect the surface irregularities and microhardness of the outer layer of the resulting workpiece. Various studies have been conducted within the framework of this classification [15–16]. Cobanoglu and Ozturk [17] investigated the surface quality and microhardness of AISI 1040 carbon steel during the roller polishing process. The parameters for the burnishing were speed, feed, and polishing force. The trial levels were performed using the Taguchi technique. An ANOVA investigation was utilized to determine the effect of each process parameter on surface and microhardness. The study revealed that the feed rate significantly affects the surface quality in the roller polishing process. Several studies have shown that the developed polishing system increases the service life of metal products and their wear resistance [18–19]. From the reviewed literature, it is found that the roller burnishing process efficiently 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 occurrence of surface defects such as scratches and cracks. However, very few studies have been reported on the modeling and optimization of roller burnishing of Al6061-T6 alloy to obtain the lowest surface roughness,

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