AUTOMATIC PROCESS BY TURNING AND SINGLE ROLLER BURNISHING PROCESS ON 6063 AL ALLOY: CONSIDERATION OF THE SPRING COMPRESSION

This research studies the feasibility of automatically combining the final turning and roller burnishing processes. To enhance both machining quality and the surface roughness of Aluminum alloy 6063.  The requirements of this material in the mirror surface, it commonly performed on several surface treatment processes and loses accuracy and time. The burnishing process is widely used to enhance the machining quality by improving the surface finish, fatigue layer, and corrosion resistance. It is mostly used in the automotive and aerospace industries to enhance the performance of the mechanical part components. However, academic research or the industrial application of the burnishing process to achieve the mirror finishing surface on Al6063 that is lower than 0.1 µm has not been well-addressed and investigated. Therefore, this research designed the single roller burnishing tool for the final fishing process by automatic tool change on the CNC turning machine.  An important part was conducted in two aspects: a review of the previous study to determine the efficiency of final turning operations to determine initial control parameters that can be achieved a surface roughness lower than 0.5 µm (Ra). and another is the continuous process by the single roller burnishing tool with 3 types of spring stiffness of 25, 40, and 80 N/mm respectively. The results showed that the spring compression with 40 N/mm can be achieved the surface roughness of 0.08 µm/80 nm (Ra) without surface waviness under the burnishing conditions of feed rate 0.05 mm/rev, spindle speed 1250 RPM, and burnishing force at 250 N. This single roller burnishing tool can be automatically reduced the surface roughness from 0.5 µm (Ra) to 0.08 µm (Ra), while the surface hardness is improved by 37%.