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<p>Orthogonal ball burnishing has emerged as a long-term finishing technique that improves surface integrity without removing any material. However, the optimization of burnishing parameters for medium-carbon steels such as XC38 has received little attention in literature, notably through statistical full factorial techniques. This study uses a 2<sup>2</sup> complete factorial experimental design to optimize the effects of burnishing force (Py: 115–150&#xa0;N) and number of passes (np: 1–3) on XC38 steel’s surface and tribological properties. Surface roughness (Ra) was reduced by up to 89.28%, microhardness increased by 48.47%, and wear resistance improved by 42.36% under ideal conditions. These findings establish orthogonal burnishing as an environmentally friendly, chip-free method for improving component life in mechanical systems where surface performance is crucial. The findings also establish a quantitative framework for process optimization that may be applied to similar medium-carbon steels utilized in industrial engineering applications.</p>

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Full Factorial Optimization of Orthogonal Burnishing for Enhanced Surface Properties and Wear Resistance of XC38 Steel

  • 期刊论文

  • 发表日期：

    2026年2月13日

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  • Hamid Hamadache,
  • Selma Belabend,
  • Mohammed Seyf Eddine Bougoffa,
  • Fathi Gharbi

摘要

Orthogonal ball burnishing has emerged as a long-term finishing technique that improves surface integrity without removing any material. However, the optimization of burnishing parameters for medium-carbon steels such as XC38 has received little attention in literature, notably through statistical full factorial techniques. This study uses a 22 complete factorial experimental design to optimize the effects of burnishing force (Py: 115–150 N) and number of passes (np: 1–3) on XC38 steel’s surface and tribological properties. Surface roughness (Ra) was reduced by up to 89.28%, microhardness increased by 48.47%, and wear resistance improved by 42.36% under ideal conditions. These findings establish orthogonal burnishing as an environmentally friendly, chip-free method for improving component life in mechanical systems where surface performance is crucial. The findings also establish a quantitative framework for process optimization that may be applied to similar medium-carbon steels utilized in industrial engineering applications.