Investigating the Influence of Tool Selection on Surface Quality in Burnished AISI 1035 Steel

Alsamanty, Mahmoud; Youssef, Waleed F.; Abdelsalam, Mohammed; Ibrahim, Abdelkader

doi:10.21608/erjsh.2023.236348.1218

Investigating the Influence of Tool Selection on Surface Quality in Burnished AISI 1035 Steel

Document Type : Research articles

Authors

¹ Department of Mechanical Engineering, Faculty of Engineering at Shoubra, Benha University, Egypt

² Department of Mechatronics and Robotics, School of Innovative Engineering Design, Egypt-Japan University of Science and Technology (E-JUST), Alexandria, Egypt.

³ Mechanical Engineering Department, Faculty of Engineering, Sinai University.

⁴ Department of Design and production engineering - faculty of Engineering - Ain Shams University, Cairo, Egypt

10.21608/erjsh.2023.236348.1218

Abstract

The metal burnishing process is a vital and modern technique for achieving high-quality surface finishes. This research uses the Taguchi and RSM (Response Surface Methodology) methods to optimize the ball burnishing process parameters. Three different tools were specifically designed and utilized in this study, and a Taguchi L16 matrix was employed for the experimental design. The results of surface roughness parameters and surface out-of-roundness were conducted. The resulting data was subjected to square regression analysis. The findings of this research demonstrate that both the tool type selected as well as the burnishing parameters significantly influence the surface roughness and out-of-roundness values. The analysis revealed intricate relationships between these factors, providing valuable insights for process optimization. Specifically, the research identified optimal parameter combinations for each tool type, leading to improved surface quality. The rigid tool exhibited minimum surface roughness at a rotational speed of 450 RPM, a feed rate of 0.09 mm/rev, and a penetration depth of 0.35 mm. While the spring tool achieved minimum surface roughness at a rotational speed of 500 RPM, a feed rate of 0.09 mm/rev, and a penetration depth of 0.35 mm. For out-of-roundness, the rigid tool exhibited minimum out-of-roundness at a rotational speed of 600 RPM, a feed rate of 0.12 mm/rev, and a penetration depth of 0.35 mm. While the spring tool achieved minimum out-of-roundness at a rotational speed of 475 RPM, a feed rate of 0.09 mm/rev, and a penetration depth of 0.20 mm.

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