Abstract
To improve the efficiency of gear machining and fatigue strength under heavy load and alternating stress, the surface integrity of 12Cr2Ni4A gear steel after ultrasonic surface rolling was investigated, and an improved gray correlation analysis for machining parameters was proposed to achieve optimal surface integrity. First, the influence law and sensitivity of rolling pressure, feed rate, and spindle speed on residual stress, hardness, and surface roughness Ra were analyzed. Subsequently, in combination with the analytic hierarchy process, the gray correlation analysis method was improved by correcting the weight distribution of rolling pressure, feed rate, spindle speed, residual stress, hardness, and surface roughness. Then, a model was built to predict the surface integrity and gray correlation degree by applying the nonlinear fitting. The results showed that rolling pressure, feed rate, and spindle speed had decreasing effects on surface integrity in decreasing order. The optimum surface integrity was achieved with a surface roughness of 0.32 μm, a Vickers hardness of 615, and a residual stress of − 650.12 MPa at a rolling pressure of 320 N, a feed rate of 0.2 mm/r, and a spindle speed of 125 r/min. The reasonable selection of optimum process parameters was beneficial in improving the surface integrity of the machined surface.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
Abbreviations
- CI :
-
Consistency index
- RI :
-
Random consistency index
- CR :
-
Consistency ratio
- SNR :
-
Signal-to-noise ratio
- A :
-
Output amplitude
- R a :
-
Surface roughness
- HV:
-
Vickers hardness
- σ :
-
Residual stress
- A n :
-
Judgment matrix
- λ max :
-
Maximum eigenvalue
- w m :
-
Weight vector
- W :
-
Weight matrix
- y ij :
-
Signal-to-noise ratio
- x ij :
-
Dimensionless data
- ε :
-
Gray correlation coefficient
- γ :
-
Gray correlation degree
- R 2 :
-
Goodness of fit
References
Bandaru S, Ng AHC, Deb K (2017) Data mining methods for knowledge discovery in multi-objective optimization: part A—survey. Expert Syst Appl 70:139–159. https://doi.org/10.1016/j.eswa.2016.10.015
Cai H, Xu Y, Xie L et al (2019) Investigation on spectrum-effect correlation between constituents absorbed into blood and bioactivities of Baizhu Shaoyao San before and after processing on ulcerative colitis rats by UHPLC/Q-TOF-MS/MS coupled with gray correlation analysis. Molecules 24:940. https://doi.org/10.3390/molecules24050940
Chaubey SK, Jain NK (2018) State-of-art review of past research on manufacturing of meso and micro cylindrical gears. Precis Eng 51:702–728. https://doi.org/10.1016/j.precisioneng.2017.07.014
Dong Y, Duan ZA (2008) New determination method for identification coefficient of grey relational grade. J xi’an Univ Arch Technol (natural Science Edition) 40(4):589–592
Dos Santos PH, NevesSant’Anna SMDQ et al (2019) The analytic hierarchy process supporting decision making for sustainable development: an overview of applications. J Clean Prod 212:119–138. https://doi.org/10.1016/j.jclepro.2018.11.270
Gupta K, Jain NK, Laubscher R (2017) Advanced gear manufacturing and finishing: classical and modern processes. Academic Press
Jiang Y, Zhao B (2022) Design- and experimental-study of the rolling-enhanced. Acoustic system for gear tooth surface. Int J Adv Manuf Technol 119:6489–6501. https://doi.org/10.1007/s00170-022-08658-7
Jiao F, Lan S, Wang Y, Zhao B (2020) Residual stress characteristics and parameters optimization of ultrasonic rolling 12Cr2Ni4A gear steel. Surf Technol 49:334–341. https://doi.org/10.16490/j.cnki.issn.1001-3660.2020.11.039
Kattoura M, Telang A, Mannava SR et al (2018) Effect of ultrasonic nanocrystal surface modification on residual stress, microstructure and fatigue behavior of ATI 718Plus alloy. Mater Sci Eng A 711:364–377. https://doi.org/10.1016/j.msea.2017.11.043
Liang X, Zuo MJ, Feng Z (2018) Dynamic modeling of gearbox faults: a review. Mech Syst Signal Process 98:852–876. https://doi.org/10.1016/j.ymssp.2017.05.024
Liu C, Liu D, Zhang X et al (2019a) Improving fatigue performance of Ti-6Al-4V alloy via ultrasonic surface rolling process. J Mater Sci Technol 35:1555–1562. https://doi.org/10.1016/j.jmst.2019.03.036
Liu C, Liu D, Zhang X et al (2019b) On the influence of ultrasonic surface rolling process on surface integrity and fatigue performance of Ti-6Al-4V alloy. Surf Coat Technol 370:24–34. https://doi.org/10.1016/j.surfcoat.2019.04.080
Liu J, Zhang X, Cui Z et al (2021) Experimental investigation on ultrasonic surface rolling of Inconel 690TT. Mater Manuf Process 36:1208–1217. https://doi.org/10.1080/10426914.2021.1905831
Malekpoor H, Chalvatzis K, Mishra N et al (2018) Integrated grey relational analysis and multibjective grey linear programming for sustainable electricity generation planning. Ann Oper Res 269:475–503. https://doi.org/10.1007/s10479-017-2566-4
Meng Z, Yuanxi Z, Yang Z (2019) Theoretical and experimental analysis of compressive residual stress field on 6061 aluminum alloy after ultrasonic surface rolling process. Proc Inst Mech Eng Part C J Mech Eng Sci 233:5363–5376. https://doi.org/10.1177/0954406219850218
Meng Y, Deng J, Zhang Y et al (2020) Tribological properties of textured surfaces fabricated on AISI 1045 steels by ultrasonic surface rolling under dry reciprocating sliding. Wear 460–461:203488. https://doi.org/10.1016/j.wear.2020.203488
Niu Y, Jiao F, Zhao B, Wang D (2017) Multiobjective optimization of processing parameters in longitudinal-torsion ultrasonic assisted milling of Ti-6Al-4V. Int J Adv Manuf Technol 93:4345–4356. https://doi.org/10.1007/s00170-017-0871-3
Patil PJ, Patil CR (2016) Analysis of process parameters in surface grinding using single objective Taguchi and multi-objective grey relational grade. Perspect Sci 8:367–369. https://doi.org/10.1016/j.pisc.2016.04.077
Pulivarti SR, Birru AK (2018) Optimization of green sand mould system using Taguchi based grey relational analysis. China Foundry 15:152–159. https://doi.org/10.1007/s41230-018-7188-1
Saaty TL, Alexander JM (1981) Thinking with models: mathematical models in the physical, biological, and social sciences. RWS Publications
Salameh JP, Cauet S, Etien E et al (2018) Gearbox condition monitoring in wind turbines: a review. Mech Syst Signal Process 111:251–264. https://doi.org/10.1016/j.ymssp.2018.03.052
Shen Y, Moghadam SM, Sadeghi F et al (2015) Effect of retained austenite—compressive residual stresses on rolling contact fatigue life of carburized AISI 8620 steel. Int J Fatigue 75:135–144. https://doi.org/10.1016/j.ijfatigue.2015.02.017
Shunmugesh K, Pratheesh A (2020) Taguchi grey relational analysis based optimization of micro-drilling parameters on carbon fiber reinforced plastics. Mater Today Proc 24:1994–2003. https://doi.org/10.1016/j.matpr.2020.03.628
Sun X, Hu Z, Li M et al (2019) Optimization of pollutant reduction system for controlling agricultural non-point-source pollution based on grey relational analysis combined with analytic hierarchy process. J Environ Manag 243:370–380. https://doi.org/10.1016/j.jenvman.2019.04.089
Wang P, Pan Y, Liu Y et al (2021) Research on surface properties of Ti-6Al-4V alloy by multi-ultrasonic rolling. Proc Inst Mech Eng Part C J Mech Eng Sci 235:5594–5602. https://doi.org/10.1177/0954406220984194
Ye H, Chen A, Liu S et al (2022) Effect of ultrasonic surface rolling process on the surface properties of QAl10--1.5 aluminum bronze alloy. Surf Coat Technol 433:128126. https://doi.org/10.1016/j.surfcoat.2022.128126
Yin M-S (2013) Fifteen years of grey system theory research: a historical review and bibliometric analysis. Expert Syst Appl 40:2767–2775. https://doi.org/10.1016/j.eswa.2012.11.002
Zhang YY, Jia Y, Li M, Hou LA (2018) Spatiotemporal variations and relationship of PM and gaseous pollutants based on gray correlation analysis. J Environ Sci Health Part A 53:139–145. https://doi.org/10.1080/10934529.2017.1383122
Zhang M, Deng J, Liu Z, Zhou Y (2019) Investigation into contributions of static and dynamic loads to compressive residual stress fields caused by ultrasonic surface rolling. Int J Mech Sci 163:105144. https://doi.org/10.1016/j.ijmecsci.2019.105144
Zhao H, Liang J, Liu C (2020a) High-speed EMUs: characteristics of technological development and trends. Engineering 6:234–244. https://doi.org/10.1016/j.eng.2020.01.008
Zhao J, Liu Z, Chen L, Hua Y (2020b) Ultrasonic-induced phase redistribution and acoustic hardening for rotary ultrasonic roller burnished Ti-6Al-4V. Metall Mater Trans A 51:1320–1333. https://doi.org/10.1007/s11661-019-05594-2
Funding
This research was supported by the National Natural Science Foundation of China (U1604255, 51875179).
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare that there is no conflict of interest regarding the publication of this paper.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Gao, G., Wang, Y., Zhao, B. et al. Multi-objective optimization of processing parameters for ultrasonic surface rolling 12Cr2Ni4A gear steel based on an improved gray correlation analysis. Multiscale and Multidiscip. Model. Exp. and Des. 6, 165–177 (2023). https://doi.org/10.1007/s41939-022-00129-6
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s41939-022-00129-6