Optimization of roller burnishing process on EN-9 grade alloy steel using response surface methodology

• Published in: Journal of the Brazilian Society of Mechanical Sciences and Engineering Vol. 39; no. 8; pp. 3089 - 3101
• Main Authors: Stalin John, M. R., Banerjee, Nilanjan, Shrivastava, Karuna, Vinayagam, B. K.
• Format: Journal Article
• Language: English
• Published: Berlin/Heidelberg Springer Berlin Heidelberg 01.08.2017; Springer Nature B.V
• Subjects: Alloy steels; Alloys; Burnishing; Electron microscopes; Engineering; Hardness; Mathematical models; Mathematical morphology; Mechanical Engineering; Numerical controls; Optimization; Response surface methodology; Roller burnishing; Scanning electron microscopy; Surface finish; Surface hardness; Surface properties; Surface roughness; Technical Paper; Tungsten carbide; Variance analysis; ANOVA analysis; Optimization technique; Response surface methodology; CNC lathe; Roller burnishing
• ISSN: 1678-5878; 1806-3691
• DOI: 10.1007/s40430-016-0674-8

The roller burnishing tool is used in computer numerical control lathe to superfinish the turning process. The tool and workpiece materials considered are tungsten carbide (69 HRC) and EN-9 Grade Alloy Steel (10 HRC), respectively. The input parameters are burnishing force, feed, roller contact width and number of passes. The response surface methodology is used to develop a mathematical model and optimize the parameters for the surface characteristics (such as surface roughness and surface hardness). The optimum surface roughness and its surface hardness are 0.2 µm and 18 HRC, respectively. The surface roughness is reduced by 94.5% and hardness is improved by 41.7%. The contributing variable of each parameter is estimated using analysis of variance method. The morphology of the burnished surface is investigated using scanning electron microscope.