FE Simulation Of Deformation And Residual Stress For Surface Rolling

Surface rolling is a very effective plastic strengthen technique to enhance the fatigue strength of the component and accessory. There are two main reasons which make the plastic strengthen technique enhance the fatigue strength. One of the reasons is that work-hardening happened at the surface of material while another is that residual stress has also been formed at the surface. It can restrain the formation and expansion of cracks. The deformation and residual stress after surface rolling have a close relationship with technical parameters. The traditional experimental research need to use a large number of human and financial resources. And it is also difficult to measure the residual stress for large-size specimen. Therefore, using simulation technology to predict the deformation and residual stress distribution after rolling has important meaning to the optimization of surface rolling process parameters and the prediction for fatigue life.FE simulation of surface rolling process is a highly nonlinear problem which contains material nonlinearity, geometry nonlinearity and contact nonlinearity. So the existing models did some simplification in specimen, movement of roller, analysis dimension and contact. These often lead to the decline the calculation accuracy and the distortion of results.Based on this, this article summarized others'research and carried out a FE simulation of surface rolling process for round stick by Marc. The main contents include the following aspects:(1) Established a mechanical model of surface rolling process of the round stick specimen, Use the elastic-plastic large strain finite analysis method to do a FE simulation of it, and gain a deformation result which agrees well with experiment. This will provide a gist to the prediction of deformation of surface rolling.(2) Deeply analyzed influence of modeling parameters (feed mode, boundary condition, contact settings, mesh, modeling objects) on the distribution of residual stress. And a residual stress results which agrees well with experiment was gained by establishing and modifying the settings of modeling parameters. This can help others to simulate residual stress better in the future.(3) Discussed the influence of the technique parameter of surface rolling (rolling quantity, feed rate and rolling velocity) to the distribution of residual stress. The results show that the value of residual stress increases with the increase of rolling quantity, and the uniformity decreases with the increase of feed rate and rotational velocity.