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

OBRABOTKAMETALLOV Vol. 26 No. 3 2024 technology Conclusions In this paper, an attempt was made to investigate the roller burnishing process of Al6061-T6 alloy. The following conclusions can be drawn: The surface roughness decreases with the increase in the cutting speed up to 360–380 rpm and then increased. Microhardness increases with the cutting speed. However, it has a certain optimum and when the cutting speed reaches 280–300 rpm, the microhardness decreases. On the other hand, the roundness error decreases with the increase in the cutting speed. The minimum error in surface roughness and roundness is obtained at feed values in the range of 0.18–0.22 mm/rev, a cutting speed of 300 rpm and three passes. However, the maximum microhardness is obtained at higher feed values. A decrease in surface roughness and microhardness, as well as an increase in the error in determining roundness are noted with an increase in the feed value to 0.2 mm/rev. However, it is noted that with an increase in the feed value to 0.2 mm/rev, these responses change for the better. The minimum roundness error and maximum microhardness are obtained using either of lower or higher feed values. However, the minimum surface roughness is obtained using a feed value in the range of 0.18–0.22 mm/rev. It is noted that the surface roughness decreases with an increase in the number of passes. However, no significant improvement in reducing the surface roughness is found after four passes. The deviation from roundness is minimized with an increase in the number of passes. And the maximum microhardness is obtained with an increase in the number of passes. The surface roughness is mostly affected by higher feed rate (nearly 30.76 %), followed by higher cutting speed and the interaction effect of cutting speed and number of passes (nearly 20 % and 15.88 %, respectively), while cutting speed and feed rate have little effect. However, the number of passes is found to be significant in reducing the surface roughness. The microhardness is mostly affected by higher cutting speed (nearly 31.02 %), followed by cutting speed (almost 16.91 %) and the number of passes and feed rate (nearly 14.87 % and 12.68 %, respectively), while feed rate and number of passes have little effect (Table 5). It is found that the roundness deviation is significantly affected by the higher feed rate (nearly 32.5 %), followed by the cutting speed (nearly 25.89 %), the interaction effect of the cutting speed and the number of passes (nearly 18.46 %), and the number of passes (nearly 15.47 %). The cutting speed of 344 rpm, feed rate of 0.25 mm/rev, and four passes are found as the optimal parameters for roller burnishing of Al6061-T6, which can obtain the minimum surface roughness of 0.807 μm, the maximum microhardness of 119.2 HV, and the minimum roundness error of 4.282 μm. References 1. El-Axir M.H. An investigation into the ball burnishing of aluminum alloy 6061-T6. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2007, vol. 221 (12), pp. 1733– 1742. DOI: 10.1243/09544054JEM818. 2. Klocke F., Liermann J. Roller burnishing of hard turned surfaces. International Journal of Machine Tools and Manufacture, 1998, vol. 38, pp. 419–423. DOI: 10.1016/S0890-6955(97)00085-0. 3. Murthy R.L., Kotiveerachari B. Burnishing of metallic surfaces – a review. Precision Engineering, 1981, vol. 3, pp. 172–179. DOI: 10.1016/01416359(81)90010-6. 4. Korzynski M. Modeling and experimental validation of the force–surface roughness relation for smoothing burnishing with a spherical tool. International Journal of Machine Tools and Manufacture, 2007, vol. 47, pp. 1956– 1964. DOI: 10.1016/j.ijmachtools.2007.03.002. 5. Hamadache H., Laouar L., Zeghib N.E., Chaoui K. Characteristics of Rb40 steel superficial layer under the ball and roller burnishing. Journal of Materials Processing Technology, 2006, vol. 180 (1–3), pp. 130–136. DOI: 10.1016/j.jmatprotec.2006.05.013. 6. Luo H., Liu J., Wang L., Zhong Q. Investigation of the burnishing force during the burnishing process with a cylindrical surfaced tool. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2006, vol. 220, pp. 893–904. DOI: 10.1243/09544054B07604.

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