Cagan Suleyman Cinar
Department of Mechanical Engineering, Mersin University, Ciftlikkoy, Mersin 33343, Türkiye.
Materials (Basel). 2025 Mar 12;18(6):1252. doi: 10.3390/ma18061252.
This study investigates the optimization of the ball burnishing process for Al8090 aluminum-lithium alloy, focusing on surface quality, mechanical properties, and sustainability metrics. A mixed-design L Taguchi experimental approach was employed to evaluate the effects of three critical parameters: burnishing force, feed rate, and number of passes under two lubrication conditions-dry and minimum quantity lubrication (MQL). Surface roughness, Brinell hardness, power and energy consumption, and carbon emissions were measured to assess technical and environmental performance. The results revealed that the MQL environment significantly improved surface roughness, achieving the lowest Ra value of 0.562 µm with a force of 200 N, a feed rate of 0.05 mm/rev, and four passes. In contrast, the highest Brinell hardness (43.6 HB) was observed in dry conditions with a force of 100 N, a feed rate of 0.1 mm/rev, and two passes. Energy consumption and carbon emissions were minimized in the MQL condition, with the lowest energy consumption recorded as 0.0169 kWh and corresponding carbon emissions of 0.0084 kg CO. These findings highlight the trade-offs between surface quality, hardness, and sustainability, providing valuable insights for optimizing the ball burnishing process for advanced materials like Al8090.
本研究探讨了Al8090铝锂合金滚珠研磨工艺的优化，重点关注表面质量、机械性能和可持续性指标。采用混合设计的L田口实验方法，评估了在干摩擦和微量润滑（MQL）两种润滑条件下，三个关键参数——研磨力、进给速度和走刀次数的影响。通过测量表面粗糙度、布氏硬度、功率和能耗以及碳排放来评估技术和环境性能。结果表明，MQL环境显著改善了表面粗糙度，在200 N的力、0.05 mm/rev的进给速度和四次走刀的条件下，达到了最低的Ra值0.562 µm。相比之下，在干摩擦条件下，100 N的力、0.1 mm/rev的进给速度和两次走刀时观察到最高的布氏硬度（43.6 HB）。在MQL条件下，能耗和碳排放降至最低，记录的最低能耗为0.0169 kWh，相应的碳排放量为0.0084 kg CO。这些发现突出了表面质量、硬度和可持续性之间的权衡，为优化Al8090等先进材料的滚珠研磨工艺提供了有价值的见解。
