Abstract
The chamfer surface of the hole entrance is considered a source of crack initiation and propagation caused by surface non-uniformity, which undoubtedly has a significant effect on component performance. The present study proposes a multi-roller taper burnishing (MRTB) process that is able to improve the integrity of the chamfer surface and thereby enhance the fatigue performance of 7050-T7451 aluminum alloy. The influence mechanism of the MRTB process on the topography, roughness, microhardness, fatigue performance, and residual stress of the internal chamfer surface was finally investigated. The results showed that the most significant surface improvement was achieved at the optimal burnishing depth of 0.07 mm. Increasing the burnishing depth to the optimal value increased the fatigue life of the samples due to the improvement of surface roughness and compressive residual stress on the chamfer surface. When the burnishing depth exceeded the optimal value, surface defects appeared, and material flowed into the hole, resulting in reduced fatigue life compared to the optimal value. Therefore, the fatigue life of MRTB-treated samples with the optimum value of burnishing depth (0.07 mm) was improved by 55 % and 36 % for thicknesses of 6 mm and 8 mm, respectively, compared to untreated samples.
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