In this study, a simple roller burnishing tool was
made to operate burnishing processes on A356/5%SiC metal
matrix composite fabricated by electromagnetic stir casting
under different parameters. The effects of burnishing speed,
burnishing force and number of burnishing passes on the
surface roughness and tribological properties were measured.
Scanning electron microscopy (SEM) graphs of themachined
surface with PCD (insert-10) tool and roller burnished surface
with tungsten carbide (WC) roller were taken into consideration
to observe the surface finish of metal matrix composites.
The mechanical properties (tensile strength, hardness, ductility)
of A356/5%SiC metal matrix composites were studied
for both unburnished samples and burnished samples. The
results revealed that the roller burnished samples of A356/
5%SiC led to the improvement in tensile strength, hardness
and ductility. In order to find out the effects of roller burnishing
process parameters on the surface roughness of A356/
5%SiC metal matrix composite, response surface methodology
(RSM) (Box–Behnken design) was used and a prediction
model was developed relevant to average surface roughness
using experimental data. In the range of process parameters,
the result shows that roller burnishing speed increases, and
surface roughness decreases, but on the other hand roller
burnishing force and number of passes increase, and surface
roughness increases. Optimum values of burnishing speed
(1.5 m/s), burnishing force (50 N) and number of passes (2)during roller burnishing of A356/5%SiC metal matrix composite
to minimize the surface roughness (predicted
1.232 lm) have been found out. There was only 5.03% error
in the experimental andmodeled results of surface roughness.
Shashi Prakash Dwivedi
,
Satpal Sharma
,
Raghvendra Kumar Mishra
. Effects of roller burnishing process parameters on surface
roughness of A356/5%SiC composite using response surface
methodology[J]. Advances in Manufacturing, 2014
, 2(4)
: 303
-317
.
DOI: 10.1007/s40436-014-0083-0
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