Improvement of roundness of cylindrical parts using hybrid electrochemical smoothing and roller burnishing process

Abstract

A novel finishing process, which integrates the merits of electrochemical smoothing (ECS) and roller burnishing (RB) is proposed in this research for improving the roundness error of cylindrical parts. This process can be used after various turning operations. Through simple equipment attachments, electrochemical smoothing-roller burnishing (ECS-RB) can follow the machining process on the same turning machine. To explore the optimum combinations of the ECS-RB process parameters in an efficient and quantitative manner, the experiments were designed on the basis of the response surface methodology (RSM) technique. The effect of ECS-RB parameters namely, burnishing force, applied voltage, interelectrode gap and workpiece rotational speed on the roundness error was studied. Experimental results indicate that the combined process effectively improves the roundness error. Therefore, the combination of ECS and RB is a feasible process by which it is possible to minimize geometrical errors.