Numerical Investigation of Lubricated Deep Rolling Process in a Complex Roller Path

Abstract

Deep rolling process is a mechanical surface treatment that provides several advantages, such as low friction on the interface between the tool and workpiece in the process, controlled profile of induced compressive residual stress to enhance the HCF and LCF strength, enhancement of the stability of the near-surface structure at high temperature, and improvement of surface finish after the process. This paper investigates the deep rolling process under lubricated condition for a complex deep rolling path. A three-dimensional finite element model incorporating the strain hardening and strain rate effects on the material responses is developed to sequentially simulate the continuous multi-axis roller motion in the process. This model can capture the horizontal and normal forces acting on the roller so that a time-varying apparent coefficient of friction can be obtained. In addition, due to the complex roller path, the model also predicts a complex residual stress distribution in the near-surface material.

Deep Rolling Techniques: A Comprehensive Review of Process Parameters and Impacts on the Material Properties of Commercial Steels

“…However, the presented FE modeling process was claimed to deliver reasonable agreement with measured parameters within the stated assumptions. J. J. Liou and T. I. El-Wardany [137] investigated residual stress states in Ti-6Al-4V alloy plate through numerical simulation of the DR process involving complex roller paths. The 3D FE simulations were performed through ABAQUS with the explicit dynamic technique.…”