Mathematical Modeling and Experimental Validation of Surface Roughness in Ball Burnishing Process

Burnishing is a cold working technique used as surface enrichment to meet the desired properties of workpiece. It improves visual properties, dimensional tolerances, fatigue strength, roughness, and hardness work material by applying appropriate pressure through complex ball burnishing tool cause plastic deformation. In current work, mathematical modeling process was carried out predict roughness considering parameters such contact radius, penetration depth, elastic rebound. Further, customized tungsten carbide (W.C.) insert having 80 HRC developed for operation. The micro-hardness resulting burnished improved from 44 48 HRC. quality up 17.1 nm polishing. Several experiments were performed selecting using model feedback. workpiece 45 nm, which resulted in automatic improvements strength seven times that virgin material. results predicted good agreement (less than 5% deviation) with experimental results. This study helps understand formation mechanism more detail. Additionally, achieved show significant improvement finish (~95%), indicating potential how fast cost-effective it is. novelty this paper lies validation our