Optimizing Roller Burnishing of Aluminum Alloy 6061-T6: Comparative Analysis of Dry and Lubricated Conditions for Enhanced Surface Quality and Mechanical Properties

The present study demonstrates the roller burnishing process of aluminum alloy 6061-T6 by using a combination of aluminum oxide and vegetable oil as a lubricant. Machining parameters were explored, varying speed (v) (range 100–300 rpm), feed (f) (range 0.1–0.3 mm), and number of passes (nop) (range 1 to 3). However, performance was measured in terms of surface roughness, microhardness, and roundness. According to the results obtained from experiments, it was found that lubrication had a significant impact on performance in terms of surface roughness, mmicrohardness and roundness. Under lubricated conditions, surface roughness ranged from 0.012 µm to 1.7 µm. However, an increase in mimicrohardnessrom 92 HV to 96 HV and an improvement in roundness from 0.07 mm up to 0.05 mm were observed. Additionally, the findings indicated that high speeds with low feed rates yielded the best results: for instance, at a feed of 0.1 mm/rev, speed (v) of 300 rpm, and number of passes of three, a surface roughness of about 0.8 µm, microhardness of approximately 94 HV, and roundness of about 0.02 mm were recorded when applying lubrication. This study demonstrates how minimal lubrication techniques can be used to improve the roller burnishing process, thereby achieving better mechanical properties and surface finishes while extending the lifespan of the burnishing tool. The study has brought about a conclusion that optimizing v and f during burnishing while including relevant lubricant helps manufacturers to realize significant product quality improvements and enhance production efficiency.