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Theoretical analysis and performance prediction on modified surface layer caused by ultrasonic surface rolling

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Abstract

Ultrasonic surface rolling process (USRP) is a prospective approach that can improve fatigue property of a workpiece by improving compressive residual stress and microhardness in the modified surface layer, as well as improving surface roughness. However, because USRP is a complicated machining process, many studies on surface properties focus on experiment test and simulation method. Thus, analytical models of the modified surface layer should be established to facilitate the design and utility of the USRP. In the present work, analytical models of residual stress, plastic strain of modified surface layer, and surface roughness are proposed on the basis of Hertz contact theory and elastic–plastic mechanics, and the effects of processing parameters on the modified surface layer are predicted using the developed models. Results of the analytical models are consistent with experiment results. Therefore, the models can be used to guide the design of the modified surface layer and identify optimal processing parameters in USRP.

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Data availability

The data supporting the findings of this study are available from the corresponding author on reasonable request.

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Acknowledgments

This work was supported by China Scholarship Council (CSC201908410361).

Funding

This work was supported by China Scholarship Council (CSC201908410361).

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Authors and Affiliations

  1. School of Mechanical and Power Engineering, Zhengzhou University, No. 100 Science Avenue, Zhengzhou, 450001, Henan, China

    Zhihua Liu, Chenhui Zhang, Hao Zhao & Dong Wang

  2. Henan Key Engineering Laboratory for Anti-Fatigue Manufacturing Technology, Zhengzhou, 450001, China

    Zhihua Liu, Chenhui Zhang, Hao Zhao & Dong Wang

  3. ICMMO/SP2M, Université Paris-Saclay, 91405, Orsay, France

    Zhihua Liu & Vincent Ji

Authors
  1. Zhihua Liu
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  2. Chenhui Zhang
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  3. Hao Zhao
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  4. Vincent Ji
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  5. Dong Wang
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Contributions

Chenhui Zhang and Hao Zhao were responsible for the experiment; Dong Wang was responsible for the guidance of the experimental work; Zhihua Liu was responsible for completing the article; Vincent Ji was responsible for the guidance of the theoretical analysis. Zhihua Liu, Chenhui Zhang, Hao Zhao, Vincent Ji, and Dong Wang were involved in the discussion and significantly contributed to making the final draft of the article. All the authors read and approved the final manuscript.

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Correspondence to Zhihua Liu.

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The authors declare that they have no conflicts of interest.

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The custom software code generated during the current study is not publicly available due to confidentiality policy.

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Liu, Z., Zhang, C., Zhao, H. et al. Theoretical analysis and performance prediction on modified surface layer caused by ultrasonic surface rolling. Int J Adv Manuf Technol 113, 1307–1330 (2021). https://doi.org/10.1007/s00170-021-06642-1

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  • DOI: https://doi.org/10.1007/s00170-021-06642-1

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