Ultrasonic-assisted ball burnishing of aluminum 6061 and AISI 1045 steel

چکیده مقاله

In the present work, experimental study was carried out to enhance the surface properties of aluminum 6061 and AISI 1045 steel plates by ultrasonic-assisted ball burnishing process. Full factorial experimental design was utilized here to find the effect of ultrasonic vibration, feed rate, and pass number on surface roughness and hardness. The results were discussed according to interaction effect of process factors for different material. It is found from the results that for conventional burnishing process, the highest surface hardness is attained at 5000 mm/min feed rate and 5 pass number, while for ultrasonic-assisted burnishing, the highest hardness is attained at 1000 mm/min feed rate and 5 pass number. On the other hand, it is found from the results that exerting ultrasonic vibration significantly enhances the hardness value and hardened depth. Also, it is found that irrespective of type of operation and material, increase in feed rate causes higher roughness, whereas increase in pass number causes reduction in roughness. Furthermore, surface roughness of ultrasonic-assisted burnishing is lower than that of conventional burnishing process. This enhancement is due to the association of both static and dynamic loading in ultrasonic-assisted burnishing process that causes microstructure modification and limits the elastic recovery of the surface.