Multi-objective optimization of slide diamond burnishing parameters for enhanced fatigue resistance of AISI 52100 steel

The relentless pursuit of a competitive edge in today's market compels manufacturers to prioritize high-quality product surfaces. This focus extends beyond aesthetics, as surface finish significantly impacts a product's functionality. Resistance to corrosion, wear, and fatigue are all heavily influenced by this crucial element. Burnishing emerges as a cost-effective solution for enhancing surface quality, making it a mainstay in industries like aerospace, biomedical, and automotive. By bolstering component reliability and performance, burnishing extends product lifespans and minimizes maintenance requirements. This study delves deeper into this topic, presenting an experimental investigation into the application of diamond sliding burnishing on AISI 52100 steel. The main objectives are to investigate the effects of burnishing parameters, such as force (py), number of passes (np), and feed (f), on surface roughness (Ra) and microhardness (Vickers). Then, a multi-objective optimization was carried out using the desirability function (DF) approach to minimize surface roughness (Ra) and simultaneously maximize microhardness. A mathematical modeling based on the response surface method was performed. The ANOVA method was used to quantify the effects of burnishing parameters as well as their interactions on surface quality and microhardness. For this purpose, a Taguchi L27 plan was adopted for experimental trial planning. The effect of burnishing on surface quality and microhardness was also investigated, it is noted that an improvement of 92 and 117% were recorded, respectively, for surface roughness and microhardness. The multi-objective optimization performed have been given the optimal burnishing parameters, using these parameters, the fatigue life of the steel increased up to 120%. Fracture analysis of fatigue failure faces revealed that burnishing produces fine striations and elongated cups on the fractured surface. In addition, the process offers a more extended fracture zone where the fractured area (AF) occupies up to 61% of the total cross section (At).