Tool profile stationarity while simulating surface plastic deformation by rolling as a process of flat periodically reproducible deformation

OBRABOTKAMETALLOV Vol. 20 No. 3 2018 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 3 2 21 Tool profile stationarity while simulating surface plastic deformation by rolling as a process of flat periodically reproducible deformation Andrey Krechetov a, * T.F. Gorbachev Kuzbass State Technical University, 28 Vesennyaya str., Kemerovo, 650000, Russian Federation a https://orcid.org/0000-0002-7569-7362, krechetovaa@kuzstu.ru Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2021 vol. 23 no. 2 pp. 54–65 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2021-23.2-54-65 Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov ARTICLE INFO Article history : Received: 03 March 2021 Revised: 16 March 2021 Accepted: 03 April 2021 Available online: 15 June 2021 Keywords : Deep rolling Technological inheritance mechanics Modeling of the accumulation of deformations and metal damage Funding The work was supported by RFBR, project number 20-08-00587. ABSTRACT Introduction. Surface plastic deformation is an effective way to improve the operating performance of machine parts. One of the promising approaches to the design of surface hardening technological processes is the technological inheritance mechanics. To calculate the hereditary parameters characterizing the accumulated deformation and damage to the metal, it is possible to simulate spinning as a process of plane fractional deformation, which significantly reduces the time required for modeling the process. However, upon rotation of the plane in which the stress-strain state is considered, the roller profile changes. The aim of the work is to assess the magnitude of the change in the roller profile in the deformation plane during deformation as an important factor ensuring the accuracy of the solution obtained. Research methods . The roll profile in the warp plane is defined by the intersection line of the roll surface and this plane. The paper presents the procedure for calculating the coordinates of the points of intersection lines, which are curves of the fourth order, depending on the geometric dimensions of the roller and the part, as well as the angle of inclination of the deformation plane. Results and discussion. To estimate the value of the roller profile change, the coordinates of the points of the intersection lines of the roller surface and the deformation plane are determined for the rolling modes corresponding to a sufficiently developed plastic deformation, the obtained lines are approximated in the coordinate system associated with the deformation plane, and the relative change in the coordinates of the intersection lines when the plane was rotated are estimated. As a result of the conducted analytical studies, it is found that even with developed plastic deformation, the relative change in the coordinates of the points of intersection lines does not exceed 0.1%. This indicates the possibility of using a stationary roller profile when simulating rolling using the plane fractional deformation model. For citation: Krechetov A.A. Tool profile stationarity while simulating surface plastic deformation by rolling as a process of flat periodically reproducible deformation. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science , 2021, vol. 23, no. 2, pp. 54–65. DOI: 10.17212/1994-6309-2021-23.2-54-65. (In Russian). ______ * Corresponding author Krechetov Andrey A. , Ph.D. (Engineering), Associate Professor T.F. Gorbachev Kuzbass State Technical University 28 Vesennyaya str., 650000, Kemerovo, Russian Federation Tel.: 8 (3842) 39-63-75, e-mail: krechetovaa@kuzstu.ru Introduction One of the most effective methods of improving the performance properties of machine parts is deep rolling, especially for increasing the fatigue strength. The surface layer hardening, the roughness reduction, and the formation of favorable compressive residual stresses can significantly increase the endurance limit and fatigue crack life of parts [1–7]. Deep rolling is used to treat both surfaces with relatively simple shapes (for example, external and internal cylindrical surfaces) and complex curved surfaces (for example, the surfaces of jet engine blades) [8]. The surface layer hardening and its depth, the surface roughness, and the distribution of residual stresses after deep rolling depend on the process parameters and the material physical and mechanical properties