Application of GRA method for multi-objective optimization of roller burnishing process parameters using a carbide tool on high carbon steel (AISI-1040) Sandeep Kumar Department of Mechanical Engineering, Anna University, Chennai, India Bedasruti Mitra Tata Consultancy Services Ltd, Mumbai, India, and Naresh Kumar Department of Mechanical Engineering, CT Institute of Engineering Management and Technology, Jalandhar, India Abstract Purpose – The purpose of this paper is to analyze and optimize the roller burnishing process parameters using the design of experiments and grey relational analysis (GRA). Design/methodology/approach – In this experimental work, the carbide burnishing tool has been selected for the machining of AISI-1040 high carbon steel to get better product quality and satisfactory machining characteristics. The material surface condition while machining, burnishing tool speed, feed rate, depth of penetration and No. of passes have been selected as process constraints to conduct experimental trials. Findings – The surface roughness (SR) and surface hardness were considered as output responses. The experimental outcomes optimized by multi-parametric optimization showed considerable improvement in the process. The roller speed and number of passes are the most significant parameters for surface hardness, whereas the surface condition and roller penetration depth have the most significance on SR. Research limitations/implications – The GRA method shows the 0.03376 improvement in grey relational grade between the experimental values and the predicted values. Practical implications – The experimental outcomes optimized by multi-parametric optimization showed the considerable improvement in the process and will facilitate steel industries to enhance and improve productivity while burnishing high carbon steel (AISI-1040). Originality/value – This research represents valid work, and the authors have no conflict of interests. Keywords Taguchi method, Multi-parametric optimization, AISI-1040 steel, Burnishing process, Carbide tool, Grey relational analysis method, Surface hardness Paper type Research paper 1. Introduction Roller burnishing is a cold work super finishing process in which material displacement takes place by plastic deformation. It is not a material removal process. The burnishing process provides a higher surface finish up to a single digit and is generally used for steel components. The roller burnishing tool offers a faster production rate, clean surface, precision and longer life of the product. Burnishing is generally a cold working operation by which a bright, polished finish is produced on the metal surface by a rubbing action that smooths out small scratch marks. In this process, the burnishing tool transverses along the Grey Systems: Theory and Application Vol. 9 No. 4, 2019 pp. 449-463 © Emerald Publishing Limited 2043-9377 DOI 10.1108/GS-03-2019-0006 Received 20 March 2019 Revised 14 May 2019 27 June 2019 Accepted 28 June 2019 The current issue and full text archive of this journal is available on Emerald Insight at: www.emeraldinsight.com/2043-9377.htm This paper represents valid work and the authors have no conflict of interests. The authors acknowledge that no funding has been granted/received for this research study and for preparation of this manuscript. 449 Application of GRA method