Multi-performance optimization of the diamond burnishing process in terms of energy saving and tribological factors

Surface characteristics can be improved using diamond burnishing. In this work, an ecological indicator (energy efficiency-EF) and tribological factors (the coefficient and friction-COF and specific wear rate-SWR) of a single diamond burnishing process were optimized. The process parameters were the burnishing speed (V), burnishing depth (D), feed rate (f), the diameter of the tip (DT), and initial average roughness (IR). An efficient cooling-lubrication device comprising the minimum quantity lubrication and Ranque–Hilsch vortex tubes was utilized to facilitate burnishing trials. The Kriging models of burnishing performances were developed regarding parameters. The CRITIC method, Crow Search Algorithm, and TOPSIS were employed to select weights and optimality. The optimizing outcomes indicated that optimal values of the V, D, f, DT, and IR were 160 m/min, 0.10 mm, 0.05 mm/rev., 7 mm, and 2.00 μm, respectively. The EF was improved by 34.1, while the COF and SWR were decreased by 33.2 and 8.1, respectively. The optimal data could be applied to practical diamond burnishing to improve energy efficiency and tribological parameters for burnished external surfaces. The optimizing technique comprising the Kriging models, CRITIC, Crow Search Algorithm, and TOPSIS could be efficiently utilized to solve complex issues for burnishing operations and other machining processes. A developed system could be applied to enhance cooling-lubrication efficiencies for different machining operations, such as turning, milling, and grinding processes. © IMechE 2023.