Burnishing of aerospace alloy: A theoretical–experimental approach

Burnishing is well known as a very effective surface enhancement method for manufacturing. The current work focuses on obtaining predictable models of surface roughness and residual stresses based on experimental data. Smoother surfaces of aerospace material modified by ball burnishing have been achieved and significant influences of process parameters on both surface roughness and maximum residual stresses are established. A second-order empirical model involving pressure, speed, and feed is developed for surface roughness prediction. The predictive values are compatible with experimental results. Pressure plays an important factor on compressive residual stresses; however, the empirical models only have qualitative compatibility with the experimental results.