Texture enhancement of X40CrMoV5-1 stainless steel sheets through ultrasonic vibration-assisted ball burnishing

Abstract This study investigates the influence of ultrasonic vibration-assisted ball burnishing on the surface texture refinement of X40CrMoV5-1 (1.2344) tool steel sheets. The main objective is to optimize surface quality by determining the most effective combinations of burnishing strategies, lateral offsets, and preload forces. The underlying hypothesis posits that ultrasonic vibrations significantly alter the material’s plastic deformation behavior under mechanical loading, enhancing surface integrity and functional properties. A full factorial experimental design was employed to systematically evaluate surface roughness parameters across different burnishing strategies and lateral offsets. The results indicate that a 0.05 mm offset yields the most significant surface texture improvements, particularly in parallel and diagonal strategies, providing enhanced roughness control and potentially contributing to increased wear resistance and component longevity. The Sq parameter was reduced to 0.1 µm, achieving an 89.74% improvement compared to the as-milled surface condition. Based on the experimental findings, the study recommends employing the parallel burnishing strategy for the second pass, utilizing a 0.05 mm lateral offset as the optimal setting, and applying a preload force within the 200–250 N range to achieve superior surface characteristics.