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 roundness error. The solution having the highest desirability level was selected as an optimum parameter and as shown in Table 7. In the present investigation, it is found that the cutting speed of 344 rpm, the feed rate of 0.25 mm/ rev, and four passes are the optimum parameters for roller burnishing of Al6061-T6 for obtaining the minimum surface roughness of 0.807 µm, the maximum microhardness of 119.2 HV, and the minimum roundness error of 4.282 µm. Based on the experimental observations and optimization studies, this study finds that the roller burnishing is the better option for obtaining better geometry of Al6061-T6 alloy part. However, this study points out that the further research is required on roller burnishing of Al6061-T6 alloys using different cooling techniques to obtain improved machined surface geometry with the surface roughness approaching 0.3–0.4 μm and higher microhardness Ta b l e 6 Constraints for optimization of process parameters Parameters Goal Min.limit Max.limit Cutting speed, V (rpm) Is in range 100 500 Feed, f (mm/rev) Is in range 0.1 0.2 Number of passes, N (mm) Is in range 1 5 Surface roughness (Ra) Minimize 0.79 0.97 Microhardness (HV) Minimize 104 125 Roundness error (Re) Minimize 1.5 13.2 Ta b l e 7 A family of optimized process parameters Sr. No. Cutting speed (V) (rpm) Feed (f) (mm/rev) No. of passes Surface roughness (Ra) (µm) Microhardness (HV) Roundness error (Re) (µm) Desirability 1 344.48 0.25 4 0.807 119.2 4.282 0.7927 2 342.62 0.25 4 0.808 119.3 4.340 0.7926 3 348.05 0.25 4 0.806 118.9 4.172 0.7925 4 347.97 0.25 4 0.805 118.8 4.206 0.7914 5 355.29 0.25 4 0.804 118.2 3.950 0.7909 6 343.96 0.25 4 0.806 119.1 4.359 0.7906 7 345.53 0.25 3.99 0.807 119.1 4.273 0.7905 8 348.67 0.25 3.98 0.806 118.7 4.195 0.7886 9 344.31 0.25 3.97 0.808 119.1 4.346 0.7872 10 335.65 0.24 4 0.805 119.3 4.781 0.7835 11 336.95 0.25 3.94 0.811 119.5 4.623 0.7816 12 342.96 0.25 3.93 0.809 118.9 4.465 0.7799 13 308.15 0.24 4 0.815 121.1 5.762 0.7627 14 315.59 0.25 3.87 0.820 120.6 5.374 0.7610 15 336.65 0.2 4 0.795 116.6 5.236 0.7350 16 349.45 0.15 4 0.840 115.6 2.645 0.7111 17 359.16 0.16 4 0.838 115.1 2.346 0.7102

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