Abstract
Roller-burnishing is used in place of other traditional methods to finish 6060-T6 Aluminum alloy. How to select the burnishing parameters to improve surface integrity (reduce surface roughness, increase surface microhardness and produce compressive residual stress) is especially crucial. This paper presents an investigation of the effect of roller-burnishing process upon surface roughness, surface microhardness and residual stress of 6061-T6 Aluminum alloy. The residual stress distribution in the surface region that was burnished is determined using a deflection-etching technique. Mathematical models correlating three process parameters; burnishing speed, burnishing depth of penetration and number of passes are established. A Group Method of Data Handling Technique, GMDH, is used. It is shown that low burnishing speed and high depth of penetration produce much better surface finish, whereas a combination of high speed with high depth leads to less surface finish because of chatter. The optimum number of passes that produces a good surface finish was found to be 3 or 4. The maximum value of compressive residual stress decreases with an increase in burnishing speed. The maximum compressive residual stress increases with an increase in burnishing depth of penetration and/or number of passes.