A comparative investigation on the surface characteristics of AISI 304 and AISI 1045 steel influenced by turning combined with ball burnishing

Burnishing is a popular superfinishing procedure in the manufacturing industry that induces plastic deformation to the finished product by the application of a highly polished and hardened deforming element known as a burnishing tool. Research work on the burnishing process is numerous. However, the reports containing the comparative investigations are lacking. In this work, the effect of ball burnishing parameters namely penetration depth, burnishing spindle speed, and number of passes has been compared and analyzed on AISI 1045 and AISI 304 steels with respect to surface roughness, hardness, wear resistance, and corrosion resistance. Results indicate that the combination of a feed rate of 0.12 mm/rev, spindle speed of 160 rpm, and penetration depth of 0.025 mm with four passes generated minimum surface roughness (AISI 1045). However, maximum surface hardness is obtained with a feed rate of 0.12 mm/rev, spindle speed of 160 rpm, and at 0.085 mm penetration depth under one pass (AISI 304). The lowest specific wear rate is achieved with a feed rate of 0.12 mm/rev at a spindle speed of 160 rpm and a penetration depth of 0.085 mm in one pass (AISI 304). The burnishing process influenced both materials, AISI 304 and AISI 1045, under varying parametric conditions. The maximum reduction in surface roughness is 68.1% for AISI 304 and 79.3% for AISI 1045, while surface hardness improves by 27% for AISI 304 and 22% for AISI 1045. Additionally, the burnishing process reduces the specific wear rate by 49.3% for AISI 304 and 45.4% for AISI 1045. The refinement of grains during the burnishing process enhances corrosion resistance compared to the unburnished surface.