Document Type : Original Article
Authors
1
Mechanical Engineering Department, Faculty of Engineering at Shoubra, Benha University, 108 Shoubra St., Cairo, Egypt. Mechatronics and Robotics Department, School of Innovative Engineering Design, Egypt-Japan University of Science and Technology (E-JUST), Alexandria, Egypt.
2
Mechanical Engineering Department, Faculty of Engineering, Sinai University, Arish, North Sinai, Egypt.
3
Department of Design and production engineering - faculty of Engineering – Ain Shams University, Cairo, Egypt.
4
Mechanical Engineering Department, Faculty of Engineering at Shoubra, Benha University, 108 Shoubra St., Cairo, Egypt
Abstract
Metal burnishing is a prominent surface finishing process that plays a significant role in enhancing surface quality. This research focuses on the optimization of ball burnishing process parameters using the Taguchi and Response Surface Methodology (RSM) approaches. The study employs three distinct tools designed for this purpose, with experiments conducted. Surface roughness and outof-roundness measurements were performed. The Taguchi method demonstrated that the rigid tool achieved minimum surface roughness at a burnishing speed of 500 rpm, a feed rate of 0.09 mm/rev, and a penetration depth of 0.35 mm. Conversely, the pneumatic tool achieved the minimum surface roughness at a burnishing speed of 600 rpm, a feed rate of 0.1 mm/rev, and a penetration depth of 0.2 mm. Regarding out-ofroundness, the rigid tool achieved minimum values at a burnishing speed of 600 rpm, a feed rate of 0.11 mm/rev, and a penetration depth of 0.35 mm. For the pneumatic tool, the minimum value was yielded at a burnishing speed of 300 rpm, a feed rate of 0.09 mm/rev, and a depth of penetration of 0.2 mm. Furthermore, the Response Surface Methodology (RSM) revealed that the rigid tool achieved the minimum surface roughness at a burnishing speed of 496.9697 rpm, a feed rate of 0.09 mm/rev, and a penetration depth of 0.35 mm. In contrast, the spring tool achieved the minimum surface roughness at a burnishing speed of 451.5152 rpm, a feed rate of 0.12 mm/rev, and a penetration depth of 0.35 mm. Regarding out-of-roundness, the rigid tool yielded the minimum values at a burnishing speed of 600 rpm, a feed rate of 0.12 mm/rev, and a penetration depth of 0.35 mm. The pneumatic tool achieved the minimum out-of-roundness at a burnishing speed of 300 rpm, a feed rate of 0.1006 mm/rev, and a penetration depth of 0.2 mm
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