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Ball burnishing (ballizing) chip less process which produces a smooth surface and surface hardness. The pressure generated by the ball exceeds a plastic deformation stage and create a new surfaces. The plastic deformation created by ball burnishing is a cold flows under pressure into the valleys surface is smooth, Ballizing is a technique for sizing and finishing holes in metal components. It is a rapid and relatively low cost process. A suitably oversized precision ball is pressed through an unfinished undersized hole, A simple tooling such as a hardened ball and a push rod is required for this process. However an intensive analysis is essential for analysing the mechanics of the process. The ball burnishing is very useful process to improve upon surface roughness and can be employed. It will help to impart compressive stress and fatigue life can be improved. The Al alloy is a difficult to machine material and burnishing is difficult process for this grade material. A low surface roughness and hardness was obtained in increasing the operating parameters. It may develop flaw and micro cracks on the surface.

Mechanism of Ball Burnishing Process for Radius of Curvature for Elastic and Plastic Deformation between Ball and Hole