Abstract
The kinematics of the deep rolling tool, contact stress, and induced residual stress in the near-surface material of a flat Ti-6Al-4V alloy plate are numerically investigated. The deep rolling tool is under multiaxis nonlinear motion in the process. Unlike available deep rolling simulations in the open literature, the roller motion investigated in this study includes penetrative and slightly translational motions. A three-dimensional finite element model with dynamic explicit technique is developed to simulate the instantaneous complex roller motions during the deep rolling process. The initial motion of the rollers followed by the penetration motion to apply the load and perform the deep rolling process, the load releasing, and material recovery steps is sequentially simulated. This model is able to capture the transient characteristics of the kinematics on the roller and contacts between the roller and the plate due to variations of roller motion. The predictions show that the magnitude of roller reaction force in the penetration direction starts to decrease with time when the roller motion changes to the deep rolling step and the residual stress distributions in the near-surface material after the material recovery step varies considerably along the roller path.
Highlights
Deep rolling is a mechanical surface treatment method in which the workpiece surface is exposed to high local mechanical load using a spherical or cylindrical type tool to induce work hardening and compressive residual stress in the near-surface material
Depending upon the controlling parameters, this process alters the mechanical behavior of the material by cold working and enhances stability of the nearsurface structure when the workpiece is exposed to a high temperature condition
The high temperature fatigue resistance is due to the formation of a nearsurface work hardened layer with a nanoscale microstructure during the deep rolling of the surface [1]
Summary
Deep rolling is a mechanical surface treatment method in which the workpiece surface is exposed to high local mechanical load using a spherical or cylindrical type tool to induce work hardening and compressive residual stress in the near-surface material. A large number of numerical simulations have been conducted using a spherical or cylindrical type of rolling tools to understand the contact stress distributions and deformation patterns during the near-rolling process, as well as residual stress profiles after the process. Other similar numerical investigation into this subject can be found in Guagliano and Vergani [8], Choi and Pan [3, 9], Majzoobi et al [10], Fu et al [11], Sayahi et al [12], and Klocke et al [13] These analyses are modeled with a spherical or cylindrical type of roller under indentation or rolling condition. Such complex roller path cannot be represented by a two-dimensional model; a three-dimensional finite element model is proposed in this paper to better understand the reaction forces, contact stress distributions, deformation patterns, and residual stresses induced by this complex roller motion in the deep rolling process
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