Abstract
This paper aims to determine the effect of the sector radius of a workpiece-deforming tool on the stress-strain state in the center of elastoplastic deformation and residual stresses in the hardened zone of the surface layer of cylindrical workpieces. A mathematical model of local loading was constructed using the finite element method and AN-SYS software. This model was used to determine the values of temporary and residual stresses and deformations, as well as the depth of plastic zone, depending on the sector radius of the working tool. The simulation results showed that, under the same loading of a cylindrical surface, working tools with different sector radii create different maximum tempo-rary and residual stresses. An assessment of the stress state was carried out for situations when the surface layer of a product is treated by workpiece-deforming tools with a different shape of the working edge. It was shown that, compared to a flat tool, a decrease in the radius of the working sector from 125 to 25 mm leads to an increase in the maximum temporary and residual stresses by 1.2–1.5 times, while the plastic zone depth increases by 1.5–2.4 times. The use of a working tool with a flat surface for hardening a cylindrical workpiece ensures minimal temporary residual stresses, com-pared to those produced by a working tool with a curved surface. A decrease in the radius of the working sector leads to an increase in temporary residual stresses by 2–7%. The plastic zone depth ranges from 1.65 to 2.55 mm when chang-ing the sector radius of the working tool.
Highlights
The technologies of surface plastic deformation (SPD) are widely used to improve the quality and mechanical properties of the surface of machined parts
A working tool with a sector radius RADIUS OF THE WORKING TOOL (Rtool) = 25 mm acts on the surface of a workpiece with a diameter Dwp = 20 mm under loading in basic modes
Our studies showed that the sector radius of the working tool has a significant effect on the stress-strain state of the surface layer of cylindrical workpieces exposed to SPD, in comparison with hardening with a working tool in the form of a flat plate
Summary
The technologies of surface plastic deformation (SPD) are widely used to improve the quality and mechanical properties of the surface of machined parts. Conventional SPD methods have a number of technological limitations when applied to hardening long-span and low-rigidity cylindrical parts, e.g. shafts and axles. Even under the conditions of low output, it is hard to achieve the specified accuracy of diametral dimensions and the stability of the geometric shape of non-rigid cylindrical parts. Another significant problem in the manufacture of such parts is the distortion of their rectilinear axis [4]. The products manufactured using SPD either fail to meet the established requirements or demonstrate failures and breakdowns in the course of further operation
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