On the influence of ultrasonic surface rolling process on surface integrity and fatigue performance of Ti-6Al-4V alloy

Liu, Chengsong; Liu, Daoxin; Zhang, Xiaohua; He, Guangyu; Xu, Xingchen; Ao, Ni; Ma, Amin; Liú, Dan

doi:10.1016/j.surfcoat.2019.04.080

Cited by 99 publications

(36 citation statements)

References 61 publications

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“…During the development of gear, high performance requirements of high precision, high speed, low noise, long service life, and heavy load, etc., have become the trend of gear manufacture. 6,47,48 Based on the requirements of high performance gear, ultrasonic vibration was comprehensively combined with conventional gear-processing methods, and achieving ultrasonic hobbing, ultrasonic shaving, ultrasonic gear shaping, ultrasonic honing, ultrasonic electrochemical machining, and ultrasonic gear grinding. The action of ultrasonic vibration dramatically enhanced the surface quality, microscopic geometry, surface integrity, and fatigue resistance.…”

Section: Review On Ultrasonic Compound Machining Of Gearsmentioning

confidence: 99%

Ultrasonic assisted machining of gears with enhanced fatigue resistance: A comprehensive review

Bie

Zhao

et al. 2022

Advances in Mechanical Engineering

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In recent years, ultrasonic-assisted machining (UAM) has been widely implemented to improve the performance and element quality of machined products. This paper comprehensively reviews the ultrasonic vibration effects on such ultrasonic vibration-assisted (UVA) processes as hobbing (UVAH), lapping (UVAL), electrochemical gear machining (UVAEGM), honing (UVAH), and grinding (UVAG), respectively. Compared with the conventional machining, the UAM significantly reduced the surface roughness, improved the surface microstructure, and quality. Considering the UAM applications surface modification and surface strengthening, the available technologies of ultrasonic impact, ultrasonic shot peening, and ultrasonic deep rolling were analyzed for gears and similar components. It was concluded that the surface was strengthened under UAM through introducing the high-amplitude and large-depth residual compressive stresses, restraining crack propagation to a certain extent, and improving the gear fatigue resistance. Finally, the ultrasonic machining effect on gear fatigue resistance was theoretically substantiated from the ultrasonic vibration system and surface integrity standpoints. This review aims to optimize the application of ultrasonic-assisted machining, in order to produce gears with enhanced fatigue resistance and surface integrity.

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Section: Review On Ultrasonic Compound Machining Of Gearsmentioning

confidence: 99%

Ultrasonic assisted machining of gears with enhanced fatigue resistance: A comprehensive review

Bie

Zhao

et al. 2022

Advances in Mechanical Engineering

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“…Figure 7 Furthermore, the phases were inclined at an angle of 30-40 degrees to the surface. Liu et al [59] explored the effect of the umber of processing stages on the microstructure of Ti6Al4V alloy processed under lubrication conditions. They noted that increasing processing stages increases affected depth and extent of refinement.…”

Section: Ti Alloysmentioning

confidence: 99%

“…On a similar note, the fatigue properties of USRP components have also demonstrated promising results due to the combination of surface hardening, grain refinement, and improved structural integrity, which can largely prevent fatigue-induced crack initiations [73]. A recent study from Liu et al [59] thoroughly explores the influence of USRP on the fatigue behavior of Ti6Al4V and its relation to surface integrity. This work set the static load, ultrasonic vibration frequency, and ultrasonic vibration amplitude to 600 N, 20 kHz, and 10 µm.…”

Section: Effect Of Usrp On Mechanical and Tribological Properties Of Engineering Materialsmentioning

confidence: 99%

Ultrasonic Surface Rolling Process: Properties, Characterization, and Applications

et al. 2021

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Ultrasonic surface rolling process (USRP) is a novel surface severe plastic deformation (SPD) method that integrates ultrasonic impact peening (UIP) and deep rolling (DR) to enhance the surface integrity and surface mechanical properties of engineering materials. USRP can induce gradient nanostructured surface (GNS) layers on the substrate, providing superior mechanical properties, thus preventing premature material failure. Herein, a comprehensive overview of current-state-of-the art USRP is provided. More specifically, the effect of the USRP on a broad range of materials exclusively used for aerospace, automotive, nuclear, and chemical industries is explained. Furthermore, the effect of USRP on different mechanical properties, such as hardness, tensile, fatigue, wear resistance, residual stress, corrosion resistance, and surface roughness are summarized. In addition, the effect of USRP on grain refinement and the formation of gradient microstructure is discussed. Finally, this study elucidates the application and recent advances of the USRP process.

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“…In addition, the internal FCIPs of the spring steel with fatigue failure were all triggered by inclusions, and the size of the inclusions was positively correlated with the increase in fatigue life. After USRP treatment on a rotating bending specimen of Ti-6Al-4V alloy (the minimum diameter of the specimen was ϕ6 mm), Liu et al [ 19 ] found that FCIP of each sample gradually moved to the inside with fewer rolling times (i.e., 748~870 μm), thereby increasing the fatigue life of the alloy. With decreasing processing times, the lower the surface roughness of the specimen was, the greater the value of the surface compressive residual stress.…”

Section: Introductionmentioning

confidence: 99%

Effects of the Ultrasonic Assisted Surface Rolling Process on the Fatigue Crack Initiation Position Distribution and Fatigue Life of 51CrV4 Spring Steel

et al. 2021

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In this paper, the effects of the fatigue crack initiation position (FCIP) on fatigue life are discussed. Different modified gradient fields (MGFs) are prepared on the surface of 51CrV4 spring steel components by an ultrasonic assisted surface rolling process (USRP). Subsequently, the fatigue behaviour of steels with different FCIPs is systematically studied. The results show that the fatigue life of steels first exhibits an increasing tendency and then a decreasing tendency with increasing distance between an FCIP and the surface. When an FCIP shifts from the surface of the sample to the interior, the fatigue crack initiation resistance on the interior is greater than that on the surface, which leads to an increase in fatigue life. However, when the FCIP further shifts towards the centre of the specimen, the stress triaxiality experienced by the fatigue source gradually increases, which results in a peak in the curve of FCIP versus fatigue life. The magnitude of this peak fatigue life is related to the change in the stress triaxiality. Moreover, according to focused ion beam-high-resolution transmission electron microscopy (FIB-HRTEM) microstructural analysis near FCIPs, under a higher stress triaxiality, the crack tip area is subject to greater stress constraints, making the multiplication and movement of dislocations in this area more difficult, resulting in the decrease in movable dislocation density. This decrease in dislocation density leads to an increase in the stress concentration and accelerates the crack growth rate, decreasing the fatigue life. Therefore, the significant change in fatigue life is controlled by the MGF and stress triaxiality.

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On the influence of ultrasonic surface rolling process on surface integrity and fatigue performance of Ti-6Al-4V alloy

Cited by 99 publications

References 61 publications

Ultrasonic assisted machining of gears with enhanced fatigue resistance: A comprehensive review

Ultrasonic assisted machining of gears with enhanced fatigue resistance: A comprehensive review

Ultrasonic Surface Rolling Process: Properties, Characterization, and Applications

Effects of the Ultrasonic Assisted Surface Rolling Process on the Fatigue Crack Initiation Position Distribution and Fatigue Life of 51CrV4 Spring Steel

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