Machining and optimization of the external diamond burnishing operation

Surface characteristics are effectively improved using diamond burnishing. This study proposes and optimizes the Ranque-Hilsch vortex tube-minimum quantity lubrication-based diamond burnishing (HMDB) operation to decrease the total carbon emission (CBE), air pollution (AP), and the maximum height of profile roughness (MPR). The HMDB factors are the spray distance (DA), spray angle (SA), pressure inlet (PI), and lubricant quantity (LQ). The Entropy method is employed to compute the weights of HMDB responses. The multi-objective optimization on the basis of ratio analysis (MOORA) is utilized to determine the best scenario. A novel manufacturing cost (MC) model is developed regarding the HMDB parameters to compute machining expenses. The observed results indicated that the optimum findings of the DA, SA, PI, and LQ were 15 mm, 45 deg., 4 Bar, and 70 ml/h, respectively, while the CBE, AP, MPR, and MC were decreased by 3.8, 26.5, 34.3, and 11.6. The optimizing technique comprising the Taguchi, Entropy, and MOORA could be named as a prominent solution to solve complicated optimization issues. The optimal data could help the machine operator to improve the HMDB performances for saving trial costs and essential efforts. The proposed hybrid cooling-lubrication system could be widely applied to different machining processes. © 2022 Taylor & Francis.