[Joshi*, 4.(5): May, 2015] ISSN: 2277-9655 (I2OR), Publication Impact Factor: 3.785 (ISRA), Journal Impact Factor: 2.114 http: // www.ijesrt.com © International Journal of Engineering Sciences & Research Technology [638] IJESRT INTERNATIONAL JOURNAL OF ENGINEERING SCIENCES & RESEARCH TECHNOLOGY OPTIMISATION OF ROLLER BURNISHING PROCESS PARAMETER ON CYLENDRICAL SURFACE ON ALUMINIUM WORK PIECES Mr.Ashwin Joshi*, Dr.R.N.Patil * M.Tech. Scholar, B V D U, College of engineering, Pune Professor & Head of Production Engineering Dept.,B V D U. College of engineering, Pune ABSTRACT In a single roller burnishing process, a hardened and polished roller is penetrated against a revolving cylindrical workpiece. Rotation of tool is parallel to the axis of rotation of the workpiece. Roller burnishing process is a superior chipless finishing process. It is done on machined or ground surfaces for both external and internal surfaces. Roller burnishing is used to improve the mechanical properties of surfaces as well as their surface finish. In this experiment cylindrical Aluminum alloy (Al-6061) workpiece has been burnished using different machining parameters [Speed, Feed, and Depth of Penetration and Number of passes.].The experiment was carried on lathe machine. It is observed that Depth of Penetration is the significant parameter to control the surface finish (Ra value). The AVOVA results are validated using the AHP method. Here regression model also derived and presented. At the end the confirmation tests conducted to confirm results with the actual Ra values. INTRODUCTION Burnishing is considered as a chipless cold working finishing process which can be used to improve surface characteristics. Surface roughness of machined components plays vital role in many fields. Surface roughness is very important factor for the functioning of machined components. As the pressure exceeds the yield point of the work piece material, plastic deformation at surface takes place. Due to this metal displacement takes place i.e. peaks on the machined surface are caused to flow into the valleys, which causes to reduce the height of the peaks in the process of Ra value of the machined surface. In this study surface roughness is the main response its variable and the parameters considered are spindle speed in rpm, tool feed in m/s, Depth of penetration in mm and number of passes.On experimental analysis, it is found that all the process parameters significantly affect the quality of surface Surface finish is achieved by flattening the rough peaks by compressive force of the rollers. A burnished surface is very smoother than any abrasively finished surface. Using the abrasive metal removal methods we can lower the roughness height. But this process it leaves sharp projections on the machined surface (Murthy R. L., 1981). Burnishing process is specially used where surface roughness value (Ra) play important roll along with super finish of surface. To control the roughness value (Ra) with different machining parameters burnishing process is used. Roller burnishing process is used produce accurately sized machined components finished with densely compacted surface. It resembles forming or cold working in contrast to micro metal abrasion in the finishing processes like honing and lapping. Two phenomena have been generally associated in the analysis of burnishing. One is flattening by plastic flow of roughness peaks and second is the displacement into adjacent valleys. Lot of research task on burnishing process was already been carried out was pointed out with the effect of the burnishing process on the surface roughness and surface hardness.Aysun Sagbas[1] analyzed and optimized surface roughness using ball burnishing, Optimization strategy was depend up the desirability function approach (DFA) together with response surface methodology (RSM) . Using Response Surface Method with rotatable central composite design (CCD) quadratic regression model was developed to predict surface roughness values.