Effect of Ball Burnishing Parameters on the Surface Roughness by a Burnishing Tool with Magnetic Ball Holding Device

Abstract

In this study four burnishing parameters were selected for optimizing the burnishing process using Taguchi method. The examined burnishing parameters include: (1) Burnishing speed, (2) Force and (3) Feed rate and (4) Ball diameter. Other parameters such as number of burnishing passes, and penetration depth are considered constant in this study. For each parameter, 5(five) levels were considered. According to Taguchi method with 4 (four) independent parameters, 25 experiments are conducted. 5 (five) coded levels were used for each parameter and MINITAB software has used for data analysis. The purpose of this work is to study the relationships between surface finish and the ball burnishing process parameters. The paper deals with the effect of burnishing process on Mild Steel using Lathe. Surface roughness generated after the turning operation was used to ball burnishing. For better response parameter a ball burnishing tool is developed with magnetic ball holding device which reduces the friction between ball and bearing. Moreover, the tool is designed for using of different ball diameter. Experimental work was carried out on a Conventional lathe and surface roughness is determined. From all experimental data a mathematical model is established by Dimensional Analysis. The optimal burnishing parameters were found for the surface roughness by using of Taguchi technique with Lower is better S/N ratio and validation of the process by Response Surface Methodology (RSM) (systematic method for using the influential factors in a process for improvement and optimization). It was found that the optimal burnishing parameters for the best surface finish was at burnishing speed of 155 rpm, burnishing feed of 0.1 mm/rev, force 78 N and ball diameter 11 mm. The effects of burnishing parameters (i.e., burnishing speed, force, feed rate and ball diameter) on the surface roughness was investigated by analysis of variance (ANOVA). It was found that the burnishing feed and ball diameter has the most influential effect on the surface roughness, followed by the burnishing force, and least influence by the speed.