OBRABOTKAMETALLOV Vol. 28 No. 2 2026 154 EQUIPMENT. INSTRUMENTS References 1. Suslov A.G. Kachestvo poverkhnostnogo sloya detalei mashin [Quality of the surface layer of machine parts]. Moscow, Mashinostroenie Publ., 2000. 320 p. ISBN 5-217-02976-5. 2. Jawahir I.S., Brinksmeier E., M’Saoubi R., Aspinwall D.K., Outeiro J.C., Meyer D., Umbrello D., Jayal A.D. Surface integrity in material removal processes: Recent advances. CIRP Annals, 2011, vol. 60 (2), pp. 603–626. DOI: 10.1016/j.cirp.2011.05.002. 3. Suslov A.G., Bez”yazychnyi V.F., Panfi lov Yu.V. Tekhnologiya i instrumenty otdelochno-uprochnyayushchei obrabotki detalei poverkhnostnym plasticheskim deformirovaniem. V 2 t. T. 2 [Technology and tools for fi nishing and Selection and justifi cation of geometric parameters of the roller contact surface for line-by-line surface plastic deformation Semen Zaydes a, Thanh Chung Le b, * Irkutsk National Research Technical University, 83 Lermontov str., Irkutsk, 664074, Russian Federation a http://orcid.org/0000-0001-9416-7749, zsa@ex.istu.edu; b http://orcid.org/0009-0003-2787-1746, lechung275@gmail.com Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2026 vol. 28 no. 2 pp. 136–156 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2026-28.2-136-156 ART I CLE I NFO Article history: Received: 03 March 2026 Revised: 16 March 2026 Accepted: 21 March 2026 Available online: 15 June 2026 Keywords: Surface plastic deformation Line-by-line processing Annular roller Contact surface geometry Finite element method Residual stresses Hardening depth Microrelief Controlled deformation constraint Modifi ed profi le ABSTRACT Introduction. The paper is devoted to the selection and justifi cation of rational geometric parameters for the contact surface of an annular roller used in line-by-line surface plastic deformation (SPD). The relevance of this work stems from the need to enhance the service performance of machine components while ensuring high surface quality and processing productivity. The purpose of the study is to determine a tool working profi le geometry that provides maximum hardening depth and compressive residual stress levels with minimal distortion of the surface microgeometry under conditions of overlapping single deformation tracks. Methods. To solve the formulated problem, the fi nite element method (FEM) implemented in the ANSYS Workbench software package (Transient Structural module) was employed, using a bilinear isotropic hardening model for Steel 45 (AISI 1045). A comparative analysis of three roller profi le types was performed: convex (toroidal), concave (profi led), and straight (cylindrical). During the computational experiment, the tool profi le radius and the circular feed step were varied. The effi ciency was evaluated based on the criteria of hardened layer depth, residual stress magnitude, and the height of plastic pile-up at the boundaries of adjacent processing tracks. Results and Discussion. It is established that the rational profi le radius for the toroidal profi le is 5.0 mm, and for the profi led roller – 15.5 mm. The disadvantages of the basic geometries are identifi ed: the toroidal roller provides a hardening depth of 1.15 mm but requires small feeds (resulting in low productivity); the profi led roller allows for increased feed, but the hardening depth decreases to 0.91 mm. It is shown that the use of a modifi ed cylindrical profi le with fi llet transitions enables the eff ect of “controlled constraint” of plastic deformation. This geometry ensures the formation of a uniform hardened layer with a depth of 1.02 mm, residual stresses of 300–320 MPa, and a micro-irregularity height of 2–5 μm. Conclusions. The application of the developed tool makes it possible to increase the productivity of the SPD process by 5 times compared to the toroidal roller without loss of surface layer quality. The obtained results can be recommended for the design of technological tooling for the fi nishing and hardening treatment of critical machine components operating under cyclic loads. For citation: Zaydes S.A., Le T.C. Selection and justifi cation of geometric parameters of the roller contact surface for line-by-line surface plastic deformation. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2026, vol. 28, no. 2, pp. 136–156. DOI: 10.17212/1994-6309-2026-28.2-136-156. (In Russian). ______ * Corresponding author Le Thanh Chung, Postgraduate Student Irkutsk National Research Technical University, 83 Lermontov str., 664074, Irkutsk, Russian Federation Tel.: +7 950 123-53-82, e-mail: lechung275@gmail.com
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