Investigations on Effect of Different Ball Burnishing Conditions on Surface Roughness Using Response Surface Methodology

Abstract

Burnishing is becoming popular post-machining surface finishing technique due to its excellent features. The use of high finish and hard, ball or roller on pre-machined surface with pressure smooths out protrusions to fill the valleys and thus, resulting in lower surface roughness. In present work, ball burnishing has been carried out on free cutting brass in different burnishing conditions such as dry (Plain Burnishing, PB), lubricated (LB) and with abrasives (Abrasive Assisted Burnishing, AAB) to establish the relationship between surface roughness and the four process parameters like burnishing force, burnishing feed, burnishing speed and number of passes. The effect of using lubricants and abrasive particles is compared over PB. Design of Experiments based on Response Surface Methodology (RSM) is adopted to develop the mathematical models of second order for each above said conditions. Analysis of Variance (ANOVA) is carried out to study the effect of burnishing parameters on response and to check the adequacy of the models developed. The results showed significant reduction in the surface roughness with all cases. Surface roughness of level 0.1043 µm can be achieved from the burnishing of the turned surface having roughness level of 2.7838 µm.