Application of response surface methodology in the optimization of burnishing parameters for surface integrity

Surface treatment is an important aspect of all manufacturing processes to impart special physical, mechanical properties. Burnishing process is a post-machining operation in which the surface irregularities of workpiece are compressed by the application of a ball, which produces a smooth compact surface and simultaneously induces compressive residual stress in. In the present study, a constant-force burnishing tool, with an interchangeable adapter for ball and roller has been newly developed and integrated with a lathe to decrease the surface roughness and increase the surface microhardness of AL6061. Ball burnishing process was carried out under different parameters while Response Surface Methodology (RSM) was used to investigate the influence of turning feed rate, burnishing force and number of tool passes on the surface integrity. The results showed that turning feed rate of 0.14 mm/r, burnishing force of 116.8 N and 2 passes produce the optimum results.