Burnishing is a low cost and environmentally friendly cold forming finishing process, wherein tool flattens the peaks. It has unique advantages such as improvement in surface finish and micro hardness at an economic cost. Associated with the burnishing process, is the flow of material into the adjacent valleys, which is being studied and reported in this paper along with the material removal analysis. Fine material removal may take place in burnishing, due to breaking of the tips.

In this study, spindle speed and feed were the input variables, along with variable tools like ball, roller and combined burnishing ones; while, surface roughness as well as surface micro hardness were the response parameters. The material used during trials was En-8. Some specimens were hard chrome plated after grinding and burnishing and the results obtained are illustrated in the paper. The findings show that spindle speed and feed have considerable effect on the response parameters. Scientifically we can use this process against traditional grinding process; since, it saves time, improves surface hardness, surface finish and reduces wastes in-terms of wear and tear of the grinding wheel as well as material.

Keywords: Roller and ball burnishing, material removal, micro hardness, chrome plating