Title: Surface study of the burnishing process when vertical high-power ultrasonics are applied

Authors: Saber Saffar; Mohammad Emadi; Mohammad Khosroabadi

Addresses: Department of Acoustics and Sound Engineering, IRIB University, P.O. Box 1986916511, Tehran, Iran ' Faculty of Engineering, Islamic Azad University, Tehran North Branch, Sadoughi Blvd., Hakimiyeh Wayout, Shahid Babaei Highway, Tehran, 1651153311, Iran ' Department of Mechanical Engineering, K.N. Toosi University, Tehran, Iran

Abstract: The effects of the high-power ultrasonic-assisted ball-burnishing process on a cylindrical 2024 aluminium specimen subjected to T4 heat treatment were investigated. Surface roughness, surface hardness, and hardened surface depth were taken as responses. The feed rate (0.05-0.11 mm/r), penetration depth (0.05-0.15 mm), and ultrasonic power (300-900 W) were herein considered as input variables of the process, assuming constant spindle speed (180 r/min) and vibration frequency (20 kHz). The results showed that the best surface roughness with vibration-free burnishing could be achieved at feed rate, V_f = 0.08 mm/r, and penetration depth, A_p = 0.15 mm. The results also showed that the surface hardness was 23% higher in ultrasonic-assisted burnishing than in vibration-free burnishing. Furthermore, maximum hardened surface depth (568 μm, 98% higher than that obtained through vibration-free burnishing) was achieved at V_f = 0.05 mm/r, A_p = 0.15 mm and P = 900 W. [Submitted 15 February 2022; Accepted 4 May 2022]

Keywords: ball burnishing; high-power ultrasonic vibrations; surface hardness; surface roughness; response surface methodology; RSM; 2024 aluminium alloy.

DOI: 10.1504/IJMR.2023.132841

International Journal of Manufacturing Research, 2023 Vol.18 No.3, pp.223 - 250

Received: 15 Feb 2022
Accepted: 04 May 2022
Published online: 11 Aug 2023 *

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