Influence of turning by burnishing on surface integrity to analyze feasibility of hybrid process

Burnishing, an ultra-precision superficial plastic deformation process, is used increasingly as a surface enhancement finishing treatment after machining operations not only to give a mirror-like and work-hardened surface but also to impose favorable compressive residual stress in it. To analyze the feasibility of turning-burnishing hybrid process, the Taguchi's L27(3(13)) orthogonal array method with the analysis of variance (ANOVA) were used to analyze the influence of the initial turning process on surface integrity of roller burnished AISI 1045 steel such as surface roughness, surface microhardness. three turning parameters, namely the cutting feed, cutting depth and cutting speed, three burnishing parameters, namely the burnishing feed, burnishing depth and burnishing speed were selected as the experimental factors in Taguchi's design of experiments to determine which one has the dominant influence and how it works on burnishing effects, namely the surface roughness and surface microhardness, the interactions between cutting feed, burnishing feed and burnishing depth were considered. The experimental results agreed well with the theoretical analysis and the conclusion is cutting feed has dominant influence on burnished surface integrity.