State of the art of Deep Rolling

Delgado, Pedro; Cuesta, I.I.; Alegre, J.M.; Díaz, Andrés

doi:10.1016/j.precisioneng.2016.05.001

Cited by 89 publications

(49 citation statements)

References 68 publications

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“…These factors affect results and need to be controlled correctly and appropriately. Compressive residual stress and work hardening near the surface of the workpiece play important roles in preventing or reducing the initiation and growth of fatigue cracks [13,14,15,16]. Consequently, FSW workpieces that have undergone the improvement processes have a longer service life.…”

Section: Introductionmentioning

confidence: 99%

Sequential Effects of Deep Rolling and Post-Weld Heat Treatment on Surface Integrity of AA7075-T651 Aluminum Alloy Friction Stir Welding

Baisukhan

Nakkiew

2019

Materials

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The aim of this research is to investigate the sequence of processes for improving the welded surface integrity of AA7075-T651 aluminum alloy joined by friction stir welding (FSW). The improvement processes that will be investigated herein include mechanical surface improvement with deep rolling (DR) and post-weld heat treatment (PWHT). Therefore, this study investigated welded surface integrity, which comprises residual stress, microhardness, surface roughness, microstructure, and fatigue life (screening). The experiment consists of three sets of combinations. In the first set, only FSW was applied; in the second set, FSW was applied, followed by DR, and then PWHT processes (FSW-DR-PWHT); and in the last set, FSW was applied, followed by PWHT, and then DR processes (FSW-PWHT-DR). Fatigue testing was carried out by undertaking a four-point bending test using a bending stress of approximately 300 MPa with a test frequency of 2.5 Hz at room temperature and stress ratio R = 0. The study found that residual stress plays an important role in the fatigue life. Finally, the fatigue test showed that FSW workpieces subject to the PWHT process followed by the DR process (FSW-PWHT-DR) had the highest fatigue life, with an increase of 239% when compared with unprocessed FSW workpieces.

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Section: Introductionmentioning

confidence: 99%

Sequential Effects of Deep Rolling and Post-Weld Heat Treatment on Surface Integrity of AA7075-T651 Aluminum Alloy Friction Stir Welding

Baisukhan

Nakkiew

2019

Materials

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“…The authors added the residual stress results into a multi axial fatigue analysis to obtain updated global safety factors for the component design. Delgado et al . elaborated a state of the art summary on deep rolling technology.…”

Section: Introductionmentioning

confidence: 99%

“…The only research that was able to fully apply real DR process conditions to a crankshaft was developed by Cevik et al 9 The authors added the residual stress results into a multi axial fatigue analysis to obtain updated global safety factors for the component design. Delgado et al 27 elaborated a state of the art summary on deep rolling technology. The authors highlighted works related to numeric simulation and to fatigue behaviour.…”

Section: Introductionmentioning

confidence: 99%

Numerical modelling of deep rolling influence over crankshaft bending and correlation with fatigue behaviour

Fonseca

Cantisano

Faria

2019

Fatigue Fract Eng Mat Struct

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The requirements for mechanical reliability of automotive crankshafts are continuously increasing, thus pushing the demand for an optimized processing. Nonetheless, the manufacturing‐induced residual stresses at critical sites for fatigue enhancement are not clarified in the state‐of‐the‐art on the topic. In particular, there is a lack of information on the effect of final manufacturing stages to improve the component life endurance, such as deep rolling, in the overall stress state while the component is under operational loads. This study deepens the validation of a finite element deep rolling model under development with the aid of an in‐house developed crankshaft resonance fatigue test rig. The stress state obtained from the deep rolling simulation was input as a predefined stress field for the simulation of operational conditions experimented at the test rig. Test results produced cracks at the fillet radii of the cast iron crankshafts as anticipated. Overlapping the fractography with the simulation's final stress field yielded interesting correlation with the crack morphology. This contributed with a strong indication of the model correctness. Moreover, it can be further implemented to indicate whether the process parameters such as roller force and angle are fully optimized for each particular crankshaft application.

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“…A field review on the deep rolling process was summarized by Delgado et al [7]. The authors highlight that most finite element models do not consider the actual Technical Editor: Lincoln Cardoso Brandao.…”

Section: Introductionmentioning

confidence: 99%

Crankshaft deep rolling analysis through energy balance simulation output

Fonseca

Faria

2019

J Braz. Soc. Mech. Sci. Eng.

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The residual stresses generated during the deep rolling process made on crankshafts are still not fully understood to this day. Comprehending and correctly simulating the process dynamics are key to investigate the process influence over the material microstructure. A numerical model using an explicit formulation was developed in order to accurately simulate deep rolling dynamics. Real boundary conditions, contact and a converged mesh were set. Diverse mass scaling and load rate were tested for comparison. The results were evaluated in terms of the simulation energy balance, as the internal, kinetic and artificial energies outputs were confronted. Conclusions could be inferred on the accuracy of the model representation of the real process based on this analysis.

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State of the art of Deep Rolling

Cited by 89 publications

References 68 publications

Sequential Effects of Deep Rolling and Post-Weld Heat Treatment on Surface Integrity of AA7075-T651 Aluminum Alloy Friction Stir Welding

Sequential Effects of Deep Rolling and Post-Weld Heat Treatment on Surface Integrity of AA7075-T651 Aluminum Alloy Friction Stir Welding

Numerical modelling of deep rolling influence over crankshaft bending and correlation with fatigue behaviour

Crankshaft deep rolling analysis through energy balance simulation output

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