Collaborative Improvement of Structure Shape and Surface Integrity in Titanium Alloy Hole Burnishing

• A two-dimensional longitudinal simplified model of hole burnishing was developed to analyze surface roughness improvement and material accumulation mechanisms. • Increasing burnishing depth improves surface integrity (roughness, residual stress, hardness) but deteriorates structure shape (material accumulation, contour, roundness). • Optimal burnishing parameters (BD=0.20 mm, spindle speed=200 r/min, feed rate=0.2 mm/r) increased fatigue life of titanium alloy TB6 holes by 162%. • The study provides a parameter selection scheme for collaborative improvement of structure shape and surface integrity in hole burnishing.