Automatic Process by Turning and Single Roller Burnishing Process on 6063 Al Alloy: Optimization and Implementation

This research studies the feasibility of automatically combining the final turning and roller burnishing processes on Aluminum alloy 6063 (Al6063). Identifying the optimal process parameters yields the desired surface quality. The burnishing process is widely used to enhance the machining quality by improving the surface finish, fatigue layer, and corrosion resistance. this research designed the single roller burnishing tool with spring constant for the final fishing process by automatic tool change on the CNC lathe machine.  An important part was conducted experimental design methods to optimize the parameters affecting the burnishing process and implementation. The results showed the parameters affecting the surface roughness after burnishing are feed rate and burnishing force. The implementation of the model prediction can be reduced the surface roughness from 0.365 µmRa to 0.090 ± 0.002µm Ra and 0.927 ± 0.04µmRz. while being able to generate the affected layer of approximately 60 µm.