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Analytical Modeling of Surface Roughness, Hardness and Residual Stress Induced by Deep Rolling

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Abstract

Deep rolling is a mechanical surface treatment that can significantly alter the features of metallic components and despite the fact that it has been used for a long time, to date the influence of the interaction among the principal process parameters has not been thoroughly understood. Aiming to fulfill this gap, this work addresses the effect of deep rolling on surface finish and mechanical properties from the analytical and experimental viewpoints. More specifically, the influence of deep rolling pressure and number of passes on surface roughness, hardness and residual stress induced on AISI 1060 steel is investigated. The findings indicate that the surface roughness after deep rolling is closely related to the yield strength of the work material and the available models can satisfactorily predict the former parameter. Better agreement between the mathematical and experimental hardness values is achieved when a single deep rolling pass is employed, as well as when the yield strength of the work material increases. Compressive residual stress is generally induced after deep rolling, irrespectively of the selected heat treatment and deep rolling parameters. Finally, the model proposed to predict residual stress provides results closest to the experimental data especially when the annealed material is considered.

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Abbreviations

δ :

Penetration of rigid ball (µm)

ν1 and ν2 :

Coefficients of Poisson of the deep rolling ball and work materials (−)

E 1 and E 2 :

Modulus of elasticity of the deep rolling ball and work materials (GPa)

F :

Deep rolling force (N)

F op :

Optimal deep rolling force (N)

R p0.2 :

Yield strength of the work material (MPa)

R m :

Ultimate tensile strength (MPa)

R t :

Maximum height of the profile after deep rolling (µm)

R ti :

Maximum height of the profile before deep rolling (µm)

h :

Roughness resulting from the feed rate of the ball (µm)

f :

Deep rolling feed rate (mm/rev)

HV0 :

Surface hardness values of the work material before deep rolling (kgf/mm2)

HV i :

Surface hardness values of the work material after deep rolling (kgf/mm2)

p :

Pressure of deep rolling (bar)

z :

Number of passes

K :

Strength coefficient

n :

Strain-hardening exponent

σ res :

Residual stress (MPa)

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Acknowledgments

The authors are indebted to the Brazilian-German Collaborative Research Initiative on Manufacturing Technology (CAPES/DFG BRAGECRIM 029/14), the German Research Foundation for funding the Collaborative Research Centre SFB 653 and CAPES Foundation, Ministry of Education of Brazil, for supporting the post-doctoral work of A.M. Abrão (Grant No. 10118128). Additional thanks go to the Institute of Materials Science of the Leibniz Universität Hannover for the heat treatment and mechanical testing of the specimens, to Ecoroll AG Werkzeugtechnik (Celle, Germany) for the provision of the deep rolling device and to Sandvik Tooling Deutschland GmbH for supplying the cutting tools.

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Authors and Affiliations

  1. Centro Federal de Educação Tecnológica de Minas Gerais, Av. Amazonas, 7675, Nova Gameleira, Belo Horizonte, MG, 30510-000, Brazil

    Frederico C. Magalhães

  2. Universidade Federal de Minas Gerais, Av. Antônio Carlos, 6627, Pampulha, Belo Horizonte, MG, 30270-901, Brazil

    Alexandre M. Abrão

  3. Institute of Production Engineering and Machine Tools, Leibniz Universität Hannover, An der Universität 2, 30823, Garbsen, Germany

    Berend Denkena, Bernd Breidenstein & Tobias Mörke

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  1. Frederico C. Magalhães
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  2. Alexandre M. Abrão
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  3. Berend Denkena
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  4. Bernd Breidenstein
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  5. Tobias Mörke
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Correspondence to Alexandre M. Abrão.

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Magalhães, F.C., Abrão, A.M., Denkena, B. et al. Analytical Modeling of Surface Roughness, Hardness and Residual Stress Induced by Deep Rolling. J. of Materi Eng and Perform 26, 876–884 (2017). https://doi.org/10.1007/s11665-016-2486-5

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  • DOI: https://doi.org/10.1007/s11665-016-2486-5

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