Wang Haojie, Wang Xiaoqiang, Tian Yingjian, Ling Yuanfei
School of Mechatronics Engineering, Henan University of Science and Technology, Luoyang, 471003, China.
Sci Rep. 2024 Oct 4;14(1):23088. doi: 10.1038/s41598-024-73884-w.
The ultrasonic rolling processing technology has been shown to significantly reduce surface roughness and enhance the residual stress of parts, thereby improving their surface properties and extending their service life. This technology is particularly effective for the precision machining and surface strengthening of ultra-high-strength steel 42CrMo. This study aims to investigate the impact of turning pre-processing on the distribution of residual stress during ultrasonic rolling, a simulation model incorporating turning pre-processing was developed and used to conduct ultrasonic rolling simulation experiments, enabling the analysis of residual stress distribution patterns. Concurrently, ultrasonic rolling strengthening experiments were performed to validate the accuracy of the simulation model. The results confirm that with increasing rotational speed and feed rate, residual stress decreases, whereas with increasing static pressure and amplitude, residual stress increases. The residual stress variation obtained from the simulation of combined turning and ultrasonic rolling closely matched the results of experimental ultrasonic rolling tests. This consistency validates the accuracy of the simulation model. This study offers a novel approach for simulating and experimentally validating ultrasonic rolling processes, particularly for shaft-like parts that undergo turning as a pre-processing step.
超声滚压加工技术已被证明能显著降低零件的表面粗糙度并增强其残余应力，从而改善其表面性能并延长其使用寿命。该技术对超高强度钢42CrMo的精密加工和表面强化尤为有效。本研究旨在探究车削预处理对超声滚压过程中残余应力分布的影响，开发了一个包含车削预处理的模拟模型并用于进行超声滚压模拟实验，从而能够分析残余应力分布模式。同时，进行了超声滚压强化实验以验证模拟模型的准确性。结果证实，随着转速和进给速度的增加，残余应力减小，而随着静压和振幅的增加，残余应力增大。车削与超声滚压联合模拟得到的残余应力变化与超声滚压实验测试结果紧密匹配。这种一致性验证了模拟模型的准确性。本研究为模拟和实验验证超声滚压过程提供了一种新方法，特别是对于经过车削预处理的轴类零件。
