Interface axial evolution process and surface integrity improvement mechanism of aluminum hole burnishing

Interface axial evolution process and surface integrity improvement mechanism of aluminum hole burnishing | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Interface axial evolution process and surface integrity improvement mechanism of aluminum hole burnishing Xiaoxuan Chen, Pingfa Feng, Jianfu Zhang, Feng Feng, Xiangyu Zhang This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7924045/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 21 Mar, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract Hole burnishing serves as a highly efficient and economical technique for improving the fatigue performance of aluminum alloy load-bearing holes. However, the effectiveness of burnishing is limited by the presence of the critical burnishing depth (BD). This study employs aluminum alloy 7050 to explore approaches for increasing the critical BD by altering the shape of the contact geometry between the tool’s roller and the workpiece. By observing the hole geometry, surface roughness, surface morphology, hardness, residual stress, and fatigue life of the workpieces’ hole wall, the impact of the roller bottom shape on the burnishing effect was investigated. The results indicated that changes in the roller bottom shape affect the rate of normal-direction deformation (NDD) and the material deformation duration (MDD), thereby influencing the processing effect. By setting the chamfer radius at the bottom of the roller to 1.25 mm, 2.5 mm, and 5 mm, it was found that tools with a radius of 2.5 mm and 5 mm achieved a critical BD larger than the original tool with a radius of 1.25 mm. Furthermore, the tool with a 2.5 mm radius resulted in better surface roughness after burnishing, and the fatigue life was maximized with 0.1 mm BD and 2.5 mm radius, representing an increase of 119.8% compared to the unburnished hole. Hole burnishing Aluminum alloy Roller bottom shape Critical burnishing depth Surface quality Fatigue life Full Text Cite Share Download PDF Status: Published Journal Publication published 21 Mar, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Minor Revisions Needed 21 Jan, 2026 Reviewers agreed at journal 22 Dec, 2025 Reviewers invited by journal 22 Dec, 2025 Editor assigned by journal 27 Oct, 2025 First submitted to journal 23 Oct, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7924045","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":563917863,"identity":"10269e81-1af1-45f2-a7e1-fa7167122d4b","order_by":0,"name":"Xiaoxuan Chen","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Xiaoxuan","middleName":"","lastName":"Chen","suffix":""},{"id":563917864,"identity":"e9b89fce-17b5-47fb-8ae0-ed8a61788d01","order_by":1,"name":"Pingfa 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burnishing\u003c/p\u003e","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing 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However, the effectiveness of burnishing is limited by the presence of the critical burnishing depth (BD). This study employs aluminum alloy 7050 to explore approaches for increasing the critical BD by altering the shape of the contact geometry between the tool’s roller and the workpiece. By observing the hole geometry, surface roughness, surface morphology, hardness, residual stress, and fatigue life of the workpieces’ hole wall, the impact of the roller bottom shape on the burnishing effect was investigated. The results indicated that changes in the roller bottom shape affect the rate of normal-direction deformation (NDD) and the material deformation duration (MDD), thereby influencing the processing effect. By setting the chamfer radius at the bottom of the roller to 1.25 mm, 2.5 mm, and 5 mm, it was found that tools with a radius of 2.5 mm and 5 mm achieved a critical BD larger than the original tool with a radius of 1.25 mm. Furthermore, the tool with a 2.5 mm radius resulted in better surface roughness after burnishing, and the fatigue life was maximized with 0.1 mm BD and 2.5 mm radius, representing an increase of 119.8% compared to the unburnished hole.\u003c/p\u003e","manuscriptTitle":"Interface axial evolution process and surface integrity improvement mechanism of aluminum hole burnishing","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-12-24 17:27:40","doi":"10.21203/rs.3.rs-7924045/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Minor Revisions Needed","date":"2026-01-21T07:18:13+00:00","index":"","fulltext":""},{"type":"reviewerAgreed","content":"","date":"2025-12-23T00:10:50+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-12-22T07:17:04+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-10-27T04:39:46+00:00","index":"","fulltext":""},{"type":"submitted","content":"The International Journal of Advanced Manufacturing Technology","date":"2025-10-24T01:12:24+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"d9cac90e-6f8a-459e-bdc4-d96c9a02b0b0","owner":[],"postedDate":"December 24th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"published-in-journal","subjectAreas":[],"tags":[],"updatedAt":"2026-03-23T16:03:15+00:00","versionOfRecord":{"articleIdentity":"rs-7924045","link":"https://doi.org/10.1007/s00170-026-17847-7","journal":{"identity":"the-international-journal-of-advanced-manufacturing-technology","isVorOnly":false,"title":"The International Journal of Advanced Manufacturing Technology"},"publishedOn":"2026-03-21 15:59:29","publishedOnDateReadable":"March 21st, 2026"},"versionCreatedAt":"2025-12-24 17:27:40","video":"","vorDoi":"10.1007/s00170-026-17847-7","vorDoiUrl":"https://doi.org/10.1007/s00170-026-17847-7","workflowStages":[]},"version":"v1","identity":"rs-7924045","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7924045","identity":"rs-7924045","version":["v1"]},"buildId":"XKTyCvWXoU3ODBz1xrDgd","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}