Optimization of Roller Burnishing Process for Improved Surface Finish, Electrical Conductivity and Grain Area for Al6061 Alloy
Kamesh B, Amrita.M1, V.S.N. Venkataramana2
1B. Kamesh, Dept. of Mechanical Engineering, Gayatri Vidya Parishad College of Engineering, Visakhapatnam, AP, India.
2Amrita.M, Dept. of Mechanical Engineering, Gayatri Vidya Parishad College of Engineering, Visakhapatnam, AP, India.
3V.S.N. Venkataramana Dept. of Mechanical Engineering, GITAM (Deemed to be University), Visakhapatnam, AP, India.
Manuscript received on November 15, 2019. | Revised Manuscript received on November 23, 2019. | Manuscript published on November 30, 2019. | PP: 442-452 | Volume-8 Issue-4, November 2019. | Retrieval Number: D6981118419/2019©BEIESP | DOI: 10.35940/ijrte.D6981.118419
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Abstract: Aluminum alloy Al6061 has wide range of applications in automobile, aircraft industries, production of parts used in medical purposes and in food processing industries. Due to high ductility of Aluminum alloys, it is difficult to get good surface finish after machining. In order to get good finish, the parts have to be burnished. The present work deals with manufacturing of burnishing tool in-house and studying the influence of different input parameters on burnishing responses. Burnishing tool is fabricated in house with chromium steel(6200z) as roller. Burnishing of Al6061alloy is performed considering input parameters as burnishing speed, feed, and burnishing force. Influence of these parameters on surface roughness, electrical conductivity and grain area is studied. Speed, feed and burnishing force with their 2-way interactions and 3-way interaction are found to have significant effect on surface roughness and electrical conductivity while only speed and feed has significant effect on grain area. Single response optimization is performed and optimum conditions which minimize surface roughness and grain area and maximize electrical conductivity separately are evaluated. Minimum surface roughness can be obtained at burnishing speed of 465rpm, feed of 0.223mm/rev and burnishing force of 125N with a percentage improvement of 51.57% with respect to the initial conditions. Maximum electrical conductivity can be obtained at burnishing speed of 290rpm, feed of 0.223mm/rev, and burnishing force of 54N with a percentage improvement of 37.09% with respect to the initial conditions. Minimum grain area can be obtained at burnishing speed of 290rpm, feed of 0.243mm/rev, and burnishing force of 125N with a percentage improvement of 37.26% with respect to the initial conditions. Initial conditions considered are burnishing speed of 100rpm, feed of 0.193mm/rev, and burnishing force of 54N. For industrial applications, optimizing single response is not desirable. Burnishing process has to be optimized considering priorities given to different responses based on applications. In the present work, multi response optimization is performed using Grey relational approach giving more and equal importance to surface roughness and electrical conductivity(0.4) and less importance to grain area(0.2). Grey relational grade showed highest improvement of 59.05% with respect to the initial design compared to single response optimization. Optimum parameters from multi response optimization are burnishing speed of 290rpm, feed of 0.243mm/rev, and burnishing force of 90N. Performing burnishing operation of Al6061 alloy at these parameters will yield best results.
Keywords: Single Optimization, Multi Response Optimization, Surface Finish, Electrical Conductivity, Grain Area.
Scope of the Article: Waveform Optimization for Wireless Power Transfer.