Surface Evaluation of a Multi-Pass Flexible Magnetic Burnishing Brush for Rough and Soft Ground 60/40 Brass

Burnishing is an advanced finishing process that produces higher-quality surfaces with better hardness and roughness than conventional finishing processes. Herein, a flexible magnetic burnishing brush comprising stainless steel pins under permanent magnet poles was used to investigate the influence of multiple passes and directions on the produced surface of soft and rough ground prepared brass. In total, five different samples were burnished on each of the two brass samples prepared. Four samples were processed in the same direction for up to four passes and the fifth sample was processed with two passes in the opposite direction. Results indicate that there was approximately a 30% increase in hardness and an 83% increase in microroughness for rougher-surface brass samples. For smoothly prepared surfaces, there was approximately a 14% increase in hardness and a 35% increase in microroughness. In the same direction of multi-pass burnishing, increasing the number of passes negatively affected surface roughness; for rougher surfaces, the surface hardness reduced and process uniformity increased owing to surface over-hardening and flaking mechanisms, and for smoother surfaces, the hardness, roughness, and process non-uniformity increased with the number of passes owing to repeated surface deformation at some locations and high flaking at other locations. Compared to single-pass burnishing, wherein the surface roughness and microhardness showed almost no change with high process uniformity, in burnishing with two opposite-direction passes, the produced surface exhibited better surface roughness, process uniformity, and microhardness improvements owing to a reverse strain mechanism. Hence, opposite burnishing passes are recommended.