Analysis of Surface Roughness and Micro-hardness in Roller Burnishing of Aluminum Alloy 6061

Burnishing is a chip-less finishing process, in which a hard roller or ball presses the surface layer of part to perform plastic deformation in the surface layer and produce improved finish, enhanced hardness and compressive residual stresses on the surface of special materials such as Aluminum and Brass. In the following research, the effect of input parameters such as feed rate, cutting speed, number of passes , burnishing force and cooling system which is applying by minimum quantity of lubrication (MQL) on surface roughness and micro-hardness in roller burnishing of Aluminum alloy 6061 has been investigated. Taguchi method is used for design of experiments and special burnishing tool is used for this research. The optimization results show that the effect of feed rate and burnishing speed is significant on surface roughness and burnishing force and the number of passes plays important role in micro-hardness. The minimum surface roughness in burnishing of aluminum alloy 6061 was 0.138 μm and the maximum was 0.475 μm. The maximum microhardness in roller burnishing Aluminum alloy 6061was found 122 HB and the minimum was 100 HB.