INVESTIGATING THE IMPACT OF DYNAMIC CHARACTERISTICS ON SURFACE QUALITY OF BURNISHED AISI 1035 STEEL USING TAGUCHI ANALYSIS

Document Type : Original Article

Authors

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

2 Mechanical Engineering Department, Faculty of Engineering at Shoubra, Benha University.

3 Department of Design and Production Engineering - Faculty of Engineering – Ain Shams University.

Abstract

The burnishing process is an important modern technology for producing mechanical parts with high-quality surface finishes. A special rigid burnishing tool was imported and used specially for the purpose of this research. Based on a Taguchi L16 matrix, an experimental test design was applied to study the effect of ball burnishing parameters as well as dynamic characteristics on the surface quality of burnished workpieces. The results of average surface roughness number, peaks counted per centimeter, out-of-roundness, and vibration amplitude were conducted. The workpieces burnished by the rigid tool retained a minimum surface roughness value of 0.107 µm at a burnishing speed of 500 RPM, 0.09 mm/rev feed rate, and 0.35 mm penetration depth. Regarding the out-of-roundness, the burnishing process using the imported rigid tool retained a minimum out-of-roundness value of 5.92 µm at a rotating speed of 600 RPM, a feed rate of 0.11 mm/rev, and a penetration depth of 0.35 mm. The increasing in vibration level achieved as the burnishing speed increases has a good effect on the surface roughness until the burnishing speed reaches a certain value. Beyond this speed value, the increase in vibration level induces the chatter phenomenon which badly affects the workpiece surface roughness. Regarding the out-of-roundness, the increasing in vibration level as the burnishing speed increases has a good impact on the roundness error of the burnished workpiece. These findings provide important insights for optimizing the metal burnishing process and achieving the desired surface quality based on the specific tool and associated factors.

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