Optimum design of compressive residual stress field caused by ultrasonic surface rolling with a mathematical model

Abstract

• An analytical study on residual stress field caused by ultrasonic surface rolling is presented. • An optimum fatigue resistance is obtained based on the study. • Analytical solutions of characteristic parameters in residual stress fields are presented. • Residual stresses in x and y directions of circular and elliptical contact areas are investigated. Compressive residual stress fields induced by ultrasonic surface rolling process play a key role in determining the fatigue performance of machine parts. The present work is an analytical approach to conducting optimum design of this field to obtain an optimum fatigue resistance. Thus, a mathematical model was presented to predict residual stresses based on circular and elliptical Hertz contact areas. Moreover, to validate the proposed analytical approach, experimental verification was carried out on 18CrNiMo7-6 steel. Analytic solutions were derived from the mathematical model and optimum characteristic parameters were obtained by investigating the characteristic parameters in this field, such as surface residual stress, maximum residual stress and its depths. Results showed that increasing the total force, Hertz contact area and ratio of the radius of tool tip to that of target body could significantly enhance the peak of compressive residual stress and its depth.