Multi-objective optimization of the flat burnishing process for energy efficiency and surface characteristics

The burnishing process is an impressive solution in order to improve the surface integrity. However, energy-efficient optimization of the burnishing process is rarely considered due to the high efforts required. This paper presented an input factor-based optimization to simultaneously enhance the power factor (PFB), the improvement of the Brinell hardness (KBH), and the reduction of the average roughness (KRa), while energy consumption (ECB) aims to decrease for the burnishing process of SKD61 steel. The burnishing speed (V), the feed (f), and the depth of penetration (d) were considered as the processing factors. The trials were conducted using the matrix generated by Taguchi. The principal component analysis (PCA) was applied to calculate the weight values of responses. The optimal parameters were determined using the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS). The results showed that the optimal values of the V, f, and d are 700 RPM, 500 mm/min, and 0.13 mm, respectively. The technical outputs are primarily influenced by the feed rate and depth of penetration. The reductions of energy consumption and surface roughness are approximately 49.48% and 13.79%, while the power factor and Brinell hardness improve around 21.80% and 56.02%, respectively, as compared to the worst case. © 2019, © 2019 Taylor & Francis.