Investigating the Influence of Tool Selection on Surface Quality in Burnished AISI 1035 Steel

Abstract

The metal burnishing process is a vital and modern technique for achieving high-quality surface finishes. This research uses the Taguchi and RSM (Response Surface Methodology) methods to optimize the ball burnishing process parameters. Three different tools were specifically designed and utilized in this study, and a Taguchi L16 matrix was employed for the experimental design. The results of surface roughness parameters and surface out-ofroundness were conducted. The resulting data was subjected to square regression analysis. The findings of this research demonstrate that both the tool type selected as well as the burnishing parameters significantly influence the surface roughness and out-of-roundness values. The analysis revealed intricate relationships between these factors, providing valuable insights for process optimization. Specifically, the research identified optimal parameter combinations for each tool type, leading to improved surface quality. The rigid tool exhibited minimum surface roughness at a rotational speed of 450 RPM, a feed rate of 0.09 mm/rev, and a penetration depth of 0.35 mm. While the spring tool achieved minimum surface roughness at a rotational speed of 500 RPM, a feed rate of 0.09 mm/rev, and a penetration depth of 0.35 mm. For out-of-roundness, the rigid tool exhibited minimum out-of-roundness at a rotational speed of 600 RPM, a feed rate of 0.12 mm/rev, and a penetration depth of 0.35 mm. While the spring tool achieved minimum out-of-roundness at a rotational speed of 475 RPM, a feed rate of 0.09 mm/rev, and a penetration depth of 0.20 mm. Additionally, the pneumatic tool yielded minimum surface roughness at a rotational speed of 600 RPM, a feed rate of 0.11 mm/rev, and a depth of penetration of 0.20 mm, with minimum out-of-roundness achieved at a rotational speed of 300 RPM, a feed rate of 0.10 mm/rev, and a depth of penetration of 0.20 mm.