Deep Rolling of Al6061-T6 Material and Performance Evaluation with New Type Designed WNMG Formed Rolling Tool

Abstract

In deep rolling, ball and roller type burnishing tools are generally used. It is generally difficult to deep roll contours with curved and conical shapes with the existing rolling tools. The aim of this study is to design experiments with a roller insert that will be an alternative to deep rolling inserts being used now and that can be fixed on the present tool holders; and to investigate the usability of them including curve and conical formed workpieces with the help of this designed tool. For this purpose, a spherical insert with a radius of 1 mm in the form of WNMG was designed based on the WNMG insert model and used in deep rolling of Al6061-T6 material using different forms and parameters. 143, 330, 495 N rolling force, 0.04, 0.08, 0.12 mm/rev feed and 400, 600, 800 rpm spindle speed were selected as rolling parameters. By examining the microhardness and surface structure of deep-rolled Al6061 parts, the achievability of the results of existing tools in deep rolling was investigated. At the end of the study, it was determined that the new type of rolling tool produced results similar to the existing tools in deep rolling in terms of microhardness and surface morphology, which enabled that the workpieces with curve and conical forms could also be rolled, and that this rolling tool could be used as an alternative in deep rolling.