Analysis and optimization of the process parameters on surface roughness in ball burnishing of AISI O2 hardened steel

• Published in: International journal of advanced manufacturing technology Vol. 128; no. 1-2; pp. 345 - 356
• Main Authors: Cica, Djordje, Kramar, Davorin
• Format: Journal Article
• Language: English
• Published: London Springer London 01.09.2023; Springer Nature B.V
• Subjects: Algorithms; Ball burnishing; Burnishing; CAE) and Design; Computer-Aided Engineering (CAD; Engineering; Industrial and Production Engineering; Machining; Mechanical Engineering; Media Management; Optimization; Original Article; Orthogonal arrays; Parameter identification; Prediction models; Process parameters; Response surface methodology; Surface roughness; Tool steels; Variance analysis; Gray wolf optimization; Surface roughness; Ball burnishing
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-023-11910-3

In this study, analysis and optimization of the machining parameters on the surface roughness in the ball burnishing process of AISI O2 hardened steel have been performed. The initial surface roughness value, ball diameter, burnishing force, burnishing speed, and burnishing feed were considered control factors, and Taguchi’s L 36 orthogonal array was employed to reduce the number of experiments. The response surface methodology (RSM) was used to develop a mathematical prediction model of the surface roughness in terms of the above parameters and to analyze interactions among the control factors as well. Additionally, analysis of variance (ANOVA) was applied to determine the significance of each burnishing parameter. The gray wolf optimization (GWO) algorithm, a relatively new bio-inspired algorithm, was introduced in the second part of the paper to obtain the optimum control factors of the ball burnishing process. Confirmation experiments were performed to verify identified optimal level of the burnishing parameters and to demonstrate the effectiveness of the GWO algorithm for the optimization of machining problems.