Investigation of the influence of surface waviness of aluminium on the burnishing quality of a combined process

Burnishing is an effective chipless finishing process for improving workpiece properties such as: hardness, vibration resistance and surface quality. Recently, the process has been increasingly applied to prismatic workpieces and free-form geometries. Before burnishing can be carried out, a milling process created the shape of the workpiece, especially for free-form surfaces. The application of different milling tools does not only produce different roughnesses, it also creates waviness which can influence the burnishing process. This publication focuses on the relationship between roughness and waviness of the milling process on the following burnishing of ductile workpiece materials. The presented work also considers the different machining directions and tool movements of this process combination. Within the evaluation the interdependence between milling and burnishing parameters are examined and the remaining frequency components of the two processes on the generated surface are compared.