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Different strategies for finite element simulations of static mechanical surface treatment processes—a comparative analysis

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Abstract

Static mechanical surface treatment (MST) processes based on the severe plastic deformation of the surface and subsurface layers improve the surface integrity (SI) of a metal component dramatically and thus its operational properties. The finite element method (FEM) is a basic simulation method used in the numerical investigations of MST processes. Although FEM always requires experimental verification of the results so obtained and an experiment to establish an adequate material constitutive model, this method saves of the researcher significant time and resources. Based on an analysis of the published studies devoted to FE simulations of static MST processes, five basic conditions have been found to be essential in order to build an adequate FE model. The theoretical formulations are then illustrated by creating FE models of the slide diamond burnishing (SDB) process using different strategies to make a comparative analysis between them. SDB is a static MST process with a thermomechanical nature. The adequacy of each FE model, respectively, strategy, is then assessed by comparing the FE results for the residual stresses with the experimental results obtained via the X-ray diffraction technique. It has been shown that a fully coupled thermal-stress 3D FE analysis of an SDB process with nonlinear kinematic hardening should be carried out. When the burnishing velocity is relatively small, the thermal effect can be neglected.

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Abbreviations

1D:

One-dimensional

2D:

Two-dimensional

3D:

Three-dimensional

BB:

Ball burnishing

CNC:

Computer numerical control

DR:

Deep rolling

FE:

Finite element

FEM:

Finite element method

MST:

Mechanical surface treatment

SB:

Slide burnishing

SDB:

Slide diamond burnishing

SI:

Surface integrity

\(A\) :

Amplitude

\(A_{5}\) :

Elongation

\(b\) :

Rate of yield surface size change

\(B\) :

Amplitude

\(c\) :

Specific heat

\(C\) :

Initial kinematic hardening modulus

\(d{}_{p}\) :

Depth of penetration

\(E\) :

Young’s modulus

\(f\) :

Feed rate

\(F_{b}\) :

Burnishing force

\(k\) :

Conductivity

\(q_{g}\) :

Heat flux density

\(Q_{\infty }\) :

Maximum change in the yield surface size

\(r\) :

Tool radius

\(R_{a}\) :

Surface roughness

\(R_{w}\) :

Workpiece radius

\(t^{*}\) :

Total time

\(T\) :

Temperature

\(v\) :

Burnishing velocity

\(z\) :

Transverse contraction

\(\alpha _{t}\) :

Coefficient of thermal expansion

\(\gamma\) :

Material coefficient

\(\Delta s\) :

Slip increment

\(\Delta t\) :

Time increment

\(\phi\) :

Full angle of rotation

\(\eta\) :

Coefficient

\(\mu\) :

Friction coefficient

\(\nu\) :

Poisson’s ratio

\(\rho\) :

Density

\(\left. \sigma \right|_{0}\) :

Yield limit of the modeled workpiece portion

\(\sigma _{u}\) :

Ultimate stress

\(\sigma _{Y}\) :

Yield limit of the bulk material

\(\tau\) :

Friction stress

\(\omega\) :

Angular velocity

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Acknowledgements

This work was supported by the European Regional Development Fund within the OP “Science and Education for Smart Growth 2014–2020,” Project CoC “Smart Mechatronics, Eco- and Energy Saving Systems and Technologies,” №BG05M2OP001-1.002-0023.

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  1. Technical University of Gabrovo, 5300, Gabrovo, Bulgaria

    J. T. Maximov, G. V. Duncheva, V. P. Dunchev & A. P. Anchev

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Maximov, J.T., Duncheva, G.V., Dunchev, V.P. et al. Different strategies for finite element simulations of static mechanical surface treatment processes—a comparative analysis. J Braz. Soc. Mech. Sci. Eng. 43, 371 (2021). https://doi.org/10.1007/s40430-021-03085-3

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