A proposed mathematical model is presented for predicting the residual stresses caused by ball bumishing, Effects of change in thTee bumishing parameters which are burnishing speed, burnishing foTce, and bumishing feed on the residual stress of 6061-T6 aluminum alloy are investigated. Theresidual stress disnibution in the surface region dueto ball burnishing is determined using a deflection-etching technique. To reduce the number of experimcnts required and build the mathematical model for

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... variables, Response Surface Methodology (RSM) is used. In addition, variancc analysis and an experimental check are conducted to determine the prominent parameters and the adequacy ofthe model. The residual stress of the bumished surface is influenced by the three parametersused. The bumishing force plays a major role and its effect can be considered as the mostimportantinputparameters. The proposed model, that offering goodcorrelation between the experimental andpredicted results, isusefu1 in selecting suitable parameters for ball bumishing process.