INFLUENCE OF FEED RATE ON SURFACE ROUGHNESS OF AL6088 ALLOY IN THE BALL BURNISHING PROCESS

Proceedings of 41st Danubia-Adria Symposium Advances in Experimental Mechanics (pp. 131-134)

 

АУТОР(И) / AUTHOR(S): Vladimir Kočović , Dragan Džunić , Sonja Kostić , Živana Jovanović Pešić , Milan Đorđević , Ljiljana Brzaković , Đorđe Vukelić

Download Full Pdf 

DOI:  10.46793/41DAS2025.131K

УВОД / INTRODUCTION:

Ball burnishing is a cold surface finishing process used to improve the roughness and other surface characteristics of aluminum alloys, resulting in enhanced wear, corrosion, and fatigue resistance. The process is based on the plastic deformation of surface irregularities using a hard, polished ball that is pressed against the workpiece under controlled forces. The key ball burnishing parameters that significantly influence the final surface roughness of aluminum include the applied force, burnishing speed, number of passes, and lubrication conditions. Studies have shown that multiple passes increase surface smoothness; however, beyond a certain threshold, additional passes do not yield substantial improvements due to saturation of plastic deformation. Moreover, moderate force levels (50–300 N) combined with low burnishing speeds (~0.05 mm/rev) have demonstrated the best results in reducing the surface roughness parameter Ra. Burnishing processes – including ball, roller, and diamond burnishing – are recognized as effective methods for enhancing the surface properties of aluminum alloys, particularly in terms of roughness reduction and hardness improvement.

КЉУЧНЕ РЕЧИ / KEYWORDS:

ПРОЈЕКАТ / ACKNOWLEDGEMENT:

This paper is the result of research conducted under the author’s contract No. 451-03-137/2025-03/200107, dated February 4, 2025, and partly supported by the Ministry of Science, Technological Development and Innovation, Republic of Serbia.

ЛИТЕРАТУРА / REFERENCES:

  • Asadbeygi, A.; Rezaei, H.; Jalali Aghchai, A. Experimental investigation and optimization of the effect of burnishing process parameters on surface roughness and hardness of Al 2036. In Proceedings of the ASME 2023 International Mechanical Engineering Congress and Exposition, Volume 3:
    Advanced Manufacturing, New Orleans, Louisiana, USA, 29 Oct–2 Nov 2023; ASME: New York, NY, USA, V003T03A022. https://doi.org/10.1115/IMECE2023-111731
  • Cagan, S.C. Surface quality and environmental impact analysis of ball burnishing on Al8090 aluminum–lithium alloy. Materials, 2025, 18, 1252. https://doi.org/10.3390/ma18061252
  • Ferencsik, V.; Varga, G. The influence of diamond burnishing process parameters on surface roughness of low-alloyed aluminium workpieces. Machines, 2022, 10, 564. https://doi.org/10.3390/machines10070564
  • Yuan, Z.; Zhou, Z.; Jiang, Z.; et al. Evaluation of surface roughness of aluminum alloy in burnishing process based on chaos theory. Chinese Journal of Mechanical Engineering, 2023, 36, 2. https://doi.org/10.1186/s10033-022-00828-8
  • Özkul, İ. Ball burnishing process effects on surface roughness for Al 6013 alloy. Turkish Journal of Engineering, 2019, 3(1), 9–13. https://doi.org/10.31127/tuje.421135
  • Dimitrov, D.M. Digital modeling and AI-driven optimization of ball burnishing process parameters. Materials Research Proceedings, 2024. https://doi.org/10.21741/9781644903377-46
  • Labuda, W.; Wieczorska, A.; Charchalis, A. The influence of the burnishing process on the change in surface hardness, selected surface roughness parameters and the material ratio of the welded joint of aluminum tubes. Materials, 2024, 17, 43. https://doi.org/10.3390/ma17010043
  • Harish; Shivalingappa, D. The influence of ball and roller burnishing process parameters on surface integrity of Al 2024 alloy. Materials Today:
    Proceedings, 2020. https://doi.org/10.1016/j.matpr.2020.02.614
  • Swirad, S. Changes in areal surface textures due to ball burnishing. Materials, 2023, 16, 5904. https://doi.org/10.3390/ma16175904
  • Amdouni, H.; Bouzaiene, H.; Montagne, A.; et al. Modeling and optimization of a ball-burnished aluminum alloy flat surface with a crossed strategy based on response surface methodology. International Journal of Advanced Manufacturing Technology, 2017, 88, 801–814. https://doi.org/10.1007/s00170-016-8817-8
  • Tadic, B.; Todorovic, P.M.; Luzanin, O.; et al. Using specially designed high-stiffness burnishing tool to achieve high-quality surface finish. International Journal of Advanced Manufacturing Technology, 2013, 67, 601–611. https://doi.org/10.1007/s00170-012-4508-2
  • Randjelovic, S.; Tadic, B.; Todorovic, P.M.; et al. Modelling of the ball burnishing process with a highstiffness tool. International Journal of Advanced Manufacturing Technology, 2015, 81, 1509–1518. https://doi.org/10.1007/s00170-015-7319-4
  • Babic, M.; Kocovic, V.; Vukelic, D.; Mihajlovic, G.; Eric, M.; Tadic, B. Investigation of ball burnishing processing on mechanical characteristics of wooden elements. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 2016, 231(1), 120–127. https://doi.org/10.1177/0954406216641711
  • Tadic, B.; Randjelovic, S.; Todorovic, P.; Zivkovic, J.; Kocovic, V.; Budak, I.; Vukelic, D. Using a high-stiffness burnishing tool for increased dimensional and geometrical accuracies of openings. Precision Engineering, 2016, 43, 335–344. https://doi.org/10.1016/j.precisioneng.2015.08.014
  • Kanovic, Z.; Vukelic, D.; Simunovic, K.; Prica, M.; Saric, T.; Tadic, B.; Simunovic, G. The modelling of surface roughness after the ball burnishing process with a high-stiffness tool by using regression analysis, artificial neural networks, and support vector regression. Metals, 2022, 12(2), 320. https://doi.org/10.3390/met12020320