Optimization of Roller Burnishing Parameters for Al7075 Using Hybrid Nanofluids: A Comparative Performance Study
Keywords:
Roller Burnishing, Al7075-T6, Hybrid Nanofluid MQL, Surface Roughness, Microhardness, Taguchi Method, Grey Relational AnalysisAbstract
Roller burnishing is a chipless surface-finishing process used to improve surface integrity while also increasing the dimensional accuracy and fatigue life of aluminum-based components through controlled cold plastic deformation. Al7075-T6 is one of the most challenging alloys to machine due to its low thermal conductivity and tendency to gall, and it generally requires a very high-quality surface finish that cannot be achieved under traditional flood-coolant conditions. This paper examines the multi-objective optimization of burnishing parameters during roller burnishing of Al7075 under five lubrication modes: dry, mineral oil, Al₂O₃/water MQL, CuO/water MQL, and Al₂O₃–CuO hybrid nanofluid MQL. For a constant penetration depth of 0.2 mm and three passes, a Taguchi L₉ orthogonal array was adopted to vary spindle speed (200–800 rpm), feed rate (0.05–0.20 mm/rev), burnishing force (100–300 N), and hybrid nanofluid concentration (0.5–1.5 wt.%). Surface roughness (Rₐ), microhardness (HV), and roundness error were evaluated as performance responses, and the dominant process parameters were identified using signal-to-noise ratio analysis and ANOVA. The aim was to quantify the surface-quality advantage of hybrid nanofluid burnishing over dry and single-nanoparticle MQL environments and to determine the parameter combination yielding both minimum Rₐ and maximum microhardness. Results show that the average surface roughness (Rₐ) obtained using the Al₂O₃–CuO hybrid nanofluid improved from 1.82 μm under dry burnishing to 0.62 μm, representing an improvement of nearly 66%, while the microhardness increased from 118 HV to 156 HV. Feed rate (35.2%) and hybrid nanofluid concentration (28.7%) were found to be the dominant process parameters. These results validate the use of hybrid nanofluid MQL as a sustainable and high-performance lubrication solution for finish burnishing of high-strength aluminum alloys.
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