Optimization of Burnishing Parameters Microhardness of Al ...

International Journal of Mechanical Engineering, ISSN: 2051-3232, Vol.43, Issue.1 1279

Optimization of Burnishing Parameters

Microhardness of Al Alloy Using RSM

Mr. Solanki Apurva L.1 Prof. V. K. Kurkute2

M Tech Scholar, Associate Professor,
Department of Mechanical Engineering, Department of Mechanical Engineering,
Bharati Vidyapeeth Deemed University College of Bharati Vidyapeeth Deemed University College of

Engineering Pune, India Engineering Pune, India
E-mail Id: [email protected] E-mail Id: [email protected]

ABSTRACT The burnishing process of metals is a cold-working
process that gives to a perfect change on the surface
Burnishing process is the transformation of a surface with profile of the work piece by a very less volume of plastic
respect to sliding contact with other surface when deformation. In the burnishing process, surface
applying burnishing pressure goes exceed the yield irregularities are redistributed without material loss.
strength of metal, the roughness of the surface is changed Comparison with chip-removal processes the burnishing
plastically and blow-out1 permanently to pour the valleys process provides several benefits. The surface hardness of
of surface so we get preferred achieved surface finish. the work piece is increases by Burnishing process, which
Advantages of burnishing are mirror-like finish, improve increase tensile strength, corrosion resistance, wears
metallurgical properties like work hardness and increase resistance, control dimensional steadiness by considering
in strength. There are different types of method to perform compressive stresses in the surface of component.
design of experiment method like ANOVA, Box-Behnken
and Response Surface Methodology (RSM).We done 1.1. Literature Review
experiment on aluminium alloy material and find the
micro hardness of the material with help of RSM. Khalid. S. Rababa et al [1] performed test and find out
“Effect of Roller Burnishing on the Mechanical Behaviour
Keywords- RSM, Burnishing Process, Optimization of and Surface Quality of O1 Alloy Steel’’ improve the
mechanical properties of the material and surface hardness
burnishing parameter, Surface micro-hardness of the O1 steel with the use of the roller burnishing
procedure. One of the most effective methods is the roller
1. INTRODUCTION burnishing. This will be achieved by putting a forcefully
and very polish roller is use beside the surface of
Burnishing process is the transformation of a surface with component.
respect to sliding contact with other surface. The Malleswara Rao J. N. , Chenna Kesava Reddy A. , Rama
burnishing process is spread the pattern of a roughness of Rao P [2] did experiment on “Study Of Roller Burnishing
surface and make it smoother. Burnishing is occurring Process On Aluminium Work Pieces Using Design Of
when any slipping surface is interaction stress permissible Experiments’’. In this experiment surface roughness is the
limit of the yield strength of component material. When main effective variable. The process variables which are
the apply burnishing force go above the yield strength of use speed, feed and number of passes of the tool. Design
the material, the surface roughness is deform plastically of Experiments methods help engineers to find out best
and blow-out forever to fill the surface roughness valleys major factor and have most important effect on output
so that required surface is reached. response.

Yeldose and Ramamoorty [3] worked for steel EN24
work material there is effective high surface finish is
given by the roller burnishing process. EN24T steel is a
standard evaluation of through-hardening alloy steel.

Luo and Liu [4] find out the highly effective burnishing
factors on the surface roughness and surface hardness.

El-Taweel and El-Axir [5] performed the study and
optimization of the ball burnishing process by Taguchi
method (DOE). They concentrate on the result of
burnishing parameters likes speed, feed, burnishing force
and number of passes on the surface hardness.

Figure 1 Burnishing

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International Journal of Mechanical Engineering, ISSN: 2051-3232, Vol.43, Issue.1 1280

El-Axir et al. [6] planned on the surface finish of 2014 different length and change the different parameter like
aluminium alloy with help of ball burnishing tool. The feed, speed, no of passes, burnishing force. Figure 4
investigation design is on the basis of RSM with CCD. shows the workpiece.

2. EXPERIMENTAL DETAILS

We are using 7178 aluminium alloy as work piece
material. Diameter of 32 mm and 100 mm length bars are
received as the work piece material. We purchase the
burnishing tool from the Bright Burnishing Tool Private
Limited. A single roller outer diameter burnishing tool
diameter of 30 mm is use. A roller burnishing tool shown
in Fig. 2 was used to perform the burnishing experiments.

Figure 2 Single Roller Burnishing Tool Figure 4 Workpiece & Hardness Graph

The experiments are performing on a general purpose type Designers used to find out the interactive and individual
effects of numbers of parameters that is the output effect
all geared lathe machine. The operations perform on the results in any design with the help of Design of
Experiments methods. DOE gives a relation between
lathe machine are turning, burnishing and wear testing. different design parameter; so, it helps to a compare one
For this purpose center type lathe machine is selected. to any standard design. DOE helps to find out sensitive
This lathe has a high precision with 10Hp spindle motor; areas and parts of the design that generates problems.
lathe machine has without step spindle speed range is 70 – Surface hardness after turning process and after
750 rpm. The center distance is 900 mm. lathe machine burnishing process is measured.
has 250 mm swing over bed and 200 mm over cross slide.
The chuck size is 148 mm diameter. It has longitudinal Correspondingly the micro hardness after turning process
feed of 0.2 – 01 mm/rev and cross feed of 0.05 – 0.52 and then burnishing process is measured by Vickers
mm/rev. In the tool holder of lathe machine burnishing hardness tester. In vicker hardness tester force is apply
tool is mount. The component is fixed with the help of with the help of diamond intender on component. The
lathe chuck and the tailstock of the lathe machine. When specifications of the vicker hardness tester are as follow:
burnishing process performing no need of any type of
coolant for cooling purpose. A figure of the burnishing
process is shown in Fig 3.

MAKE: OMNI TECH PVT. LTD. PUNE
MODEL: MVH-1, TEST LOAD (AUTOMATIC)-IOGM-
IOOOGM,
MEASURING LEAST COUNT: 0.5 pm TO 175 pm,
MAGNIFICATIONS POWER: 100 X TO 600 X

Figure 3 Experimental Setup

Perform the turning operation on workpiece on the lathe
machine. After we perform the burnishing operation at

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International Journal of Mechanical Engineering, ISSN: 2051-3232, Vol.43, Issue.1 1281

4. RESULTS AND DISCUSSION

In the experimental planning there are four factors
consider. The experiments are prearranged permitting
Taguchi examination with L25 orthogonal array. The
experimentations are carrying out with changed factor and
their altered levels given below:

Sr No. Table 1 Factors and Levels No. of
Pass
Speed Feed Force
RPM mm/RPM N

1 76 0.4 2 1

2 105 0.5 4 2

3 285 0.6 6 3

Figure 5 Micro Hardness Tester 4 460 0.7 8 4

Then average value of two diagonals of rhombus is 5 725 0.8 10 5
measured and multiplied by factor depending on
magnification lenses Table 2 Observation table

Figure 6 Diamond Intender Impression Sr Speed Feed Forc No. Hard Predicted
no. RPM mm/ eN of ness Hardness
3. RESPONSE SURFACE RPM Pas VHN
METHODOLOGY s VHN

Machinability of a material is a machining process which 1 76 0.4 2 1 103 102.8
provides a response of its process ability to be
manufactured. Machinability is defined as minimum 2 76 0.5 4 2 111 111.4
numbers of combination of parameters like accuracy and
work piece characteristics, low cutting force, low tool 3 76 0.6 5 3 112 113.7
wear rate, high material removal rate, and good
breakdown of chips. 4 76 0.7 8 4 115 115.0

Response surface methodology (RSM) is used for forming 5 76 0.8 10 5 118 116.1
and optimizing the response it is a group of calculated and
arithmetical procedures. In CNC machining centre for 6 105 0.4 4 3 113 110.4
super finish the milling process ball and roller burnishing
tools are used. 7 105 0.5 6 4 111 114.2

The input parameters are feed, force, step-over, ball 8 105 0.6 8 5 116 115.3
diameter, roller width, no of passes, speed and the output
parameters like micro Vickers hardness and surface 9 105 0.7 10 1 118 116.8
roughness values. The characteristic of burnishing process
is analysed using ANOVA analysis. The using response 10 105 0.8 2 2 102 102.2
surface methodology output parameters are modelled and
optimized. The influence surface roughness and cutting 11 285 0.4 6 5 113 114.1
force factors are identify with the help of RSM. With help
of mathematical modelling these relationships is 12 285 0.5 8 1 117 117.6
quantified.
13 285 0.6 10 2 117 117.0

14 285 0.7 2 3 100 100.7

15 285 0.8 4 4 113 110.0

16 460 0.4 8 2 115 117.7

17 460 0.5 10 3 118 117.1

18 460 0.6 2 4 100 99.6

19 460 0.7 4 5 108 109.0

20 460 0.8 6 1 111 112.6

21 725 0.4 10 4 118 98.7

22 725 0.5 2 5 98 99.1

23 725 0.6 4 1 111 111.6

24 725 0.7 6 2 113 112.4

25 725 0.8 8 3 116 113.2

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International Journal of Mechanical Engineering, ISSN: 2051-3232, Vol.43, Issue.1 1282

The analysis of variance (ANOVA) is calculated for
checking the accuracy of the model. Table 4 and Table 5
are shows the result of ANOVA analysis for surface
hardness. For the surface hardness and surface roughness
the final ratio of mean sum of parameters to mean sum of
investigational error must calculate.

Table: 3 ANOVA table for surface Hardness

Factor DOF SS MS F

Speed 4 8.56 2.14E+00 1.2663

Feed 4 8.56 2.14E+00 1.2663

Force 4 887.36 2.22E+02 131.2663

Passes 4 6.16 1.54E+00 0.9112

ERROR 8 13.52 1.69E+00 DESIGN-EXPERT Plot

TOTAL 24 924.16 4.84E-03 StdErr of Design
X = A: Speed
From the F-table, For F0.025, 4, 8 is 5.053. So f- table Y = B: FeedStdErr of Design
shows that the burnishing force is major important
element for surface hardness. Actual Factors
C: Force = 6.00
5. CONCLUSION D: Passes = 3.00

In this experiment, the effects of the four factors are feed 2.31153
rate, speed, burnishing force and numbers of passes
investigate using DOE and Response surface 1.87527
methodology. RSM is effective and optimal method for
optimizing of surface hardness and roughness. DOE with 1.43901
RSM is to define the effects of burnishing elements on the
surface roughness and surface hardness of Aluminium 1.00274
alloy. Burnishing force is determined as significant factor
on the surface hardness and surface roughness. The 0.566482
special effects of separate factor on surface roughness and
surface hardness are as bellows: 725.00

1. Burnishing Speed: 562.75

When Speed of machine increases, surface roughness 0.80 400.50
reduces reaches to lower value and then rise similarly 0.70 A: Speed
surface hardness increased reaches to high value and 0.60
again decreases. 238.25
2. Burnishing Feed:
0.50
When feed increases, surface roughness rises reach to
high value and then drop down similarly feed increases 0.40 76.00
surface hardness reduces.
B: Feed
3. Burnishing Force:
Figure 7 Surface Hardness
When applying Force increases, both surface smoothness
and surface hardness increases REFERENCES

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International Journal of Mechanical Engineering, ISSN: 2051-3232, Vol.43, Issue.1 1283

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