Aluminium 2024 alloys are widely used in the manufacturing of aircraft structural components due to high strength-to-weight ratio, excellent resistance to fatigue crack propagation, good fracture toughness, and good machinability. However, the combined effect of local corrosion and cyclic loading leads to crack initiation and propagation during service, ultimately reducing the fatigue life of the component. To address this challenge, mechanical surface treatment (MST) methods, particularly ball burnishing, have emerged as promising post-machining finishing processes. This method induces surface compressive residual stresses, which are used to enhance fatigue performance and improve service life. The present thesis aims to develop an efficient 3D Finite Element Model for the ball burnishing process applied to Aluminium 2024 through a hybrid Explicit-Implicit FEM approach for accurate residual stress prediction.