Multi-response performance optimization of burnishing operation for improving hole quality

Improving hole quality in the burnishing operation is a necessary demand to enhance its applications in different industrial aspects. The purpose of this investigation is to optimize process parameters, including the burnishing speed (Vs), depth of penetration (dp), and feed rate (Vf) for decreasing cylindricity (CL), circularity (CC), dimensional deviation (DD), and burnishing roughness (BR) under the minimum quantity lubrication (MQL). Firstly, the working principle of the MQL-based internal roller burnishing (MBIRB) operation has been proposed. A set of burnishing trials is performed using the Taguchi design of experiment. The gray relational analysis (GRA) is utilized to compute the weight value of each response, while the combined compromise solution (CCS) is employed to set the best optimal solution. Moreover, empirical models of technological performances are proposed regarding process parameters with the aid of the response surface method (RSM). The results indicated that the optimal outcomes of the Vs, dp, and Vf were 600 rpm, 0.06 mm, and 100 mm/min, respectively, while the CL, CC, DD, and BR were decreased 80.8, 2.1, 48.0, and 54.4%, respectively, as compared to the worst case. The CL, CC, and BR were reduced by 88.3, 60.0, and 93.4%, respectively, in comparison with the pre-machined characteristics. Furthermore, the predictive models of the burnishing responses could be utilized in the burnishing operation to predict the performance values with the cost-effectiveness and less manufacturing damage. © 2021, The Brazilian Society of Mechanical Sciences and Engineering.