Modeling and Evaluation of Energy Efficiency of New Hybrid Turning-Burnishing Process in Terms of Surface Properties

Abstract

The combination of the turning and burnishing process is an efficient approach to improve machined quality and productivity. This paper aims to optimize energy efficiency (EF), improved hardness ratio (IHR), and decreased roughness ratio (DRR) of a new hybrid turning-burnishing process. The machining parameters are the feed rate (f), turning speed (v), depth of cut (a), burnishing pressure (p), and the diameter of the compressing ball (d). A new turning-burnishing tool using compressed air has been designed and fabricated. A set of experiments for Aluminum Alloy 5083 were performed using the Taguchi method. The weightage principal component analysis (WPCA) and Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) were applied to obtain the weight values and optimal outcomes. The results indicated that optimum values of the depth of cut, pressure, diameter, feed rate, and speed are 1.00 mm, 0.4 MPa, 16.00 mm, 0.084 mm/rev, and 120 m/min, respectively. The improvements in the EF and IHR are by 20.75% and 8.23% respectively, while the DDR is decreased by 19.05%, as compared to common values.

Optimization of the Internal Roller Burnishing Process for Energy Reduction and Surface Properties

“…A further feed rate and/or speed may cause excessive burnishing temperature, and the residual stress can be relieved; hence, the Rockwell hardness value is decreased. Similar impacts of the spindle speed and feed rate on the machined hardness were presented in the works of [17], [18], [24], [25], and [26].…”

“…A higher degree of plastic deformation is generated; hence, higher Rockwell hardness is obtained. An increased hardness with higher burnishing depth and the number of rollers can be found in the works of [17], [18], [24], [25], and [26].…”

Modelling the Influence of Slide Burnishing Parameters on the Surface Roughness of Shafts Made of 42CrMo4 Heat-Treatable Steel

“…This phenomenon was also observed by Ibrahim [ 51 ] and Dwivedi et al [ 54 ]. Higher roller burnishing speed increases the surface temperature of a workpiece [ 54 , 55 ] and the material forming the asperities is more susceptible to plastic deformation.…”

The Influence of Diamond Burnishing Process Parameters on Surface Roughness of Low-Alloyed Aluminium Workpieces

“…Burnishing is a distinguished process to improve surface properties, in which the profile irregularities will be formed under the effect of burnishing force by tool based on the principle of sliding friction. No chips, sparks or dust are generated during machining; in addition, the need for coolant is minimal and can sometimes be omitted, so we can implement environmentally friendly and cost-effective machining [29][30][31][32]. This is preferred for finishing of hydraulic and other cylinders, pistons, bearing housings, bushings and pins [9,22].…”