Comparative evaluation of roller burnishing of Al6061-T6 alloy under dry and nanofluid minimum quantity lubrication conditions

OBRABOTKAMETALLOV Vol. 26 No. 4 2024 TECHNOLOGY conditions. The experimental results of roller burnishing of Al6061-T6 alloy under dry cutting conditions are given in [20]. Response Surface Methodology (RSM) was the main method used to analyze the experimental results. Finding the region of interest where the response(s) reach its optimal or near-optimal value was another goal of using RSM in addition to investigating the response(s) in the entire factor space. In order to understand the physics of the process, an analysis of the experimental data was performed to create regression equations for surface roughness (Ra), microhardness (HV), and roundness error (Re). Using Stat-Ease Design Expert® (version 7.0), the regression approach was used to determine the values of the coeffi cients in the equation. The equations developed for the responses in terms of actual values of surface roughness, microhardness and roundness error under dry conditions can be found in [20], and the equations for determining the responses when using nanofl uid under MQL conditions are given below: 1.4209 0.00064 4.0943 0.2224 0.00275 0.00019 0.025 Ra V f N Vf VN fN = − − − − − + + 6 2 2 2 3.11 10 13.4545 20.042 V f N − + × + + (1) 85.3181 0.213 40.1136 6.3238 0.325 0.00625 47.5 HV V f N Vf VN fN = + + − − + + − 2 2 2 0.0002 90.91 0.3522 V f N − − − (2) Ta b l e 3 Roller burnishing experimental matrix with responses Cutting speed (V) (rpm) Feed (f) (mm/rev) No. of passes Surface roughness (Ra) (μm) Microhardness (HV) Roundness error ( Re) (μm) Dry NFMQL Dry NFMQL Dry NFMQL 300 0.2 3 0.81 0.62 117 128 7.7 4.8 200 0.15 2 0.82 0.68 114 120 9.6 5.6 200 0.15 4 0.89 0.69 116 118 8.6 4.8 200 0.25 2 0.92 0.77 116 122 5.4 8.8 200 0.25 4 0.9 0.78 125 131 8.7 7.7 400 0.15 2 0.94 0.78 118 129 10.1 3.4 400 0.15 4 0.84 0.71 111 131 1.6 3.2 400 0.25 2 0.97 0.81 110 126 8.4 9.2 400 0.25 4 0.79 0.75 113 136 2.9 7.4 300 0.2 3 0.81 0.61 117 128 8.4 5.5 300 0.2 3 0.81 0.61 117 128 8.6 5.7 100 0.2 3 0.92 0.72 112 108 13.2 9 500 0.2 3 0.93 0.75 104 131 4.2 6.1 300 0.1 3 0.94 0.70 123 121 1.5 2.8 300 0.3 3 0.96 0.79 124 132 2 9.2 300 0.2 1 0.95 0.83 123 119 8.7 7.7 300 0.2 5 0.86 0.73 125 133 4 3.6 300 0.2 3 0.83 0.65 117 125 6.9 5.2 300 0.2 3 0.82 0.61 113 128 8.3 5.4 300 0.2 3 0.81 0.62 118 131 8.7 5.9

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