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Relationship between surface characteristics and the fatigue life of deep rolled AISI 4140 steel

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Abstract

Deep rolling is an effective and economically viable mechanical surface treatment that induces surface deformation by the action of a rolling tool. It is capable of reducing roughness, increasing hardness, and inducing compressive residual stresses on the workpiece surface, thus increasing the fatigue strength of the component. This behavior, however, is only achieved with use of suitable parameters. This work investigates the surface characteristics and fatigue life of hardened AISI 4140 steel subjected to turning followed by deep rolling under distinct conditions. The findings indicates that for the turned samples, roughness increases with turning feed rate, resulting in fatigue life reduction. Deep rolling promotes a reduction in surface roughness, promotes surface deformation, and causes an increase in both surface hardness and fatigue life. Surprisingly, the samples with the highest surface roughness after turning achieved the longest fatigue lives after deep rolling. The areal power spectral density analysis of the surface topography was able to identify distinct effects of deep rolling for each level of pressure used. The morphology analysis indicates an initial loss of orientation, followed by the creation of a new orientation after deep rolling under high pressures. Furthermore, the interaction between deep rolling feed and deep rolling pressure presents a significant effect on the roughness parameters, indicating that different behaviors depend on each parameter level used. Deep rolling also affects the form of the fatigue fracture, reducing the number of nucleation sites, and modifying the final overload fracture site.

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Funding

The authors acknowledge the financial support provided by the Coordination for the Improvement of Higher Education Personnel-Brazil (CAPES) under Code 001.

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  1. Graduate Program in Mechanical Engineering, Universidade Federal de Minas Gerais, Av. Antônio Carlos, 6627 Campus Pampulha, Belo Horizonte, MG, 31270-901, Brazil

    Augusto Moura Martins, Diogo Azevedo de Oliveira, Frederico de Castro Magalhães & Alexandre Mendes Abrão

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  1. Augusto Moura Martins
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  2. Diogo Azevedo de Oliveira
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  3. Frederico de Castro Magalhães
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  4. Alexandre Mendes Abrão
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Correspondence to Augusto Moura Martins.

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Martins, A.M., Oliveira, D.A.d., de Castro Magalhães, F. et al. Relationship between surface characteristics and the fatigue life of deep rolled AISI 4140 steel. Int J Adv Manuf Technol 129, 1127–1143 (2023). https://doi.org/10.1007/s00170-023-12332-x

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