Simulation and Research on deep rolling process parameters

Deep rolling is a kind of mechanical surface treatments that can improve surface quality, dimensional accuracy and mechanical properties of the parts. Compressive residual stresses generated by the process reduce the tensile stresses during loading into the workpiece. The distribution of residual stress induced by deep rolling can be influenced by rolling parameters; such as overlap of the rolling tracks, friction coefficient between roller and target plate, deep rolling force and deep rolling mechanical tools. In the present research, the effects of these parameters are studied by finite-element simulations. The results indicate that: (I) increasing overlap results in increasing magnitude of the maximum residual stress.  (II) Increases in the coefficient of friction results in decrease magnitude of the maximum residual stress and for coefficient of friction more than ۰.۱ the effect of friction can cause contraction. (III) Increase in the force intensity results in increase magnitude of the maximum residual stress. (IV) The deep rolling with mechanical tools and spring force provides a higher residual stress than the roller with constant force mode.