Optimization of Burnishing Parameters by the Application of Design of Experiments

The present work is an attempt to optimize the process parameters of the roller burnishing operation, for improved surface finish, by the application of design of experiments (DOE). The parameters considered for the present study were tool material, tool diameter and number of passes. Taguchi's L4 orthogonal array for three factors and two levels was chosen for the study. The work-piece used for the study was medium leaded brass of 25mm diameter. The results showed that high carbon high chromium steel roller of 25 mm diameter, with 3 tool passes will produce the best surface finish. The number of tool passes was found to be the parameter that had the most predominant affect on the surface finish, amongst the selected parameters for the study. Analysis of variance (ANOVA) was applied to study the affect of the untested parameters (noise) on the process parameters and the significance factor of each parameter were determined. The results obtained from Taguchi's fractional factorial approach were then compared with those from full factorial experimentation.