DESIGN AND DEVELOPMENT OF MULTI ROLL BURNISHING TOOL FOR THE SURFACE FINISHING OF ALUMINUM 7075 CYLINDER LINERS by Jeevesh Sharma
The burnishing process is a chipless finishing process in which the metal surface is plastically deformed. Most of the work in the past is done on the ball burnishing and single roller burnishing. The ball burnishing process has a disadvantage of limited feed which leads to longer cycle times and in the workpiece of longer length, the load applied is limited in both the cases of ball burnishing and roller burnishing as it could bend the workpiece. Therefore, an attempt has been made to develop a tool which removes the limitations of previous works. Multi roll burnishing tool has been developed to finish the inside of the Aluminum 7075-cylinder liner surface. Taguchi method is used to study the effect and contribution of the burnishing parameters such as speed (rpm), feed and number of passes. Trend of surface roughness revealed that maximum surface finish is obtained at low speed and intermediate level of passes. The feed comes out to be an insignificant parameter. Trend of surface hardness revealed that maximum hardness is obtained at minimum speed and maximum number of passes. The feed rate comes out to be insignificant in this case also. The contribution of parameters is found to be accurate at 95% confidence level.