Optimization and Analysis of Roller Burnishing Process on AL7075 Alloy Using Minimum Quantity Lubrication

Abstract

This study investigates the optimization of roller burnishing process parameters for AL7075 aluminum alloy under minimum quantity lubrication conditions. The experimental investigation employs Taguchi's L9 orthogonal array design to evaluate the influence of spindle speed (500-1000 rpm), feed rate (0.1-0.3 mm/rev), and number of passes (1-5) on surface roughness and hardness. Signal-to-noise ratio analysis and analysis of variance were conducted to identify optimal parameter combinations for both single-objective and multi-objective optimization scenarios. Results demonstrate that the number of passes significantly influences both surface roughness and hardness, with five passes yielding maximum hardness of 236 HB. For surface roughness minimization, the optimal combination identified was 500 rpm spindle speed, 0.2 mm/rev feed rate, and 3 passes, achieving a surface roughness of approximately 0.424 μm. Multi-objective optimization revealed a trade-off between minimizing surface roughness and maximizing hardness, with the Taguchi additive model providing a balanced parameter set. The findings contribute to enhanced understanding of roller burnishing optimization for aluminum alloys, offering practical guidelines for industrial applications requiring superior surface integrity and mechanical properties.