Abstract: Structured surfaces, owing to their excellent drag-reducing and lubrication properties, have become an important means of improving the functional performance of mechanical equipment surfaces. To fabricate structured surfaces on the outer cylindrical surface of workpieces, this paper proposes a manufacturing method based on roller burnishing with sinusoidal motion of a steel ball. To realize this method, a sinusoidal burnishing motion model was established, and computer simulations were conducted to analyze the influence of burnishing motion parameters on the morphology of the structured surface. The results show that the proposed steel-ball sinusoidal burnishing method can effectively achieve the fabrication of structured surfaces on outer cylinders. During the axial feed burnishing process, the characteristics of the structured surface can be modified by adjusting vibration frequency, amplitude, and axial feed rate; by selecting appropriate vibration frequency, amplitude, and feed rate, a uniform mesh-like structure can be obtained.