Modeling and evaluation of energy efficiency of new hybrid turning-burnishing process in terms of surface properties

The combination of the turning and burnishing process is an efficient approach to improve machined quality and productivity. This paper aims to optimize energy efficiency (EF), improved hardness ratio (IHR), and decreased roughness ratio (DRR) of a new hybrid turning-burnishing process. The machining parameters are the feed rate (f), turning speed (v), depth of cut (a), burnishing pressure (p), and the diameter of the compressing ball (d). A new turning-burnishing tool using compressed air has been designed and fabricated. A set of experiments for Aluminum Alloy 5083 were performed using the Taguchi method. The weightage principal component analysis (WPCA) and Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) were applied to obtain the weight values and optimal outcomes. The results indicated that optimum values of the depth of cut, pressure, diameter, feed rate, and speed are 1.00 mm, 0.4 MPa, 16.00 mm, 0.084 mm/rev, and 120 m/min, respectively. The improvements in the EF and IHR are by 20.75% and 8.23% respectively, while the DDR is decreased by 19.05%, as compared to common values. © 2020 by the authors.