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<p>The ultrasonic surface rolling process (USRP) represents a novel approach to surface strengthening. It is employed to enhance components' fatigue life and wear resistance by introducing residual compressive stress and inducing work hardening in the surface layer of the workpiece. The traditional planar USRP exhibits low processing efficiency. To address this, an eccentric planar ultrasonic surface rolling device has been proposed to improve the aforementioned process. A theoretical model of residual stress on the surface of the workpiece is established and numerically simulated by MATLAB, based on Hertzian contact theory and elastic-plasticity theory. Experiments are conducted to investigate the behavior of a plane rolling on a TC4 titanium alloy. This study aims to investigate the influence of machining parameters, including ultrasonic amplitude, feed rate, spindle speed, and rolling depth, on surface residual stress and hardness. The results demonstrate that the USRP can elevate the residual compressive stress on the surface of the workpiece by 5–18.5%, with the residual compressive stress reaching as high as − 639.08&#xa0;MPa. Furthermore, the average enhancement rate of the surface hardness of the workpiece is 8.9%, with the surface hardness of the workpiece reaching up to 489.7 HV, in comparison to that of the conventional surface rolling process (CSRP). The discrepancy between the theoretical residual stress value and the actual value is 3.7–13.1%, which validates the precision of the model.</p>

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Modeling and Experimental Validation of Residual Stresses on the Surface of TC4 Titanium Alloy by Eccentric Ultrasonic Surface Rolling Process

  • 期刊论文

  • 发表日期：

    2025年1月3日

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  • Jinglin Tong,
  • Hongqing Tao,
  • Shuaikun Yang,
  • Yanqiu Ye,
  • Haojie Zhai,
  • Xinbo Li,
  • Linxuan Liu,
  • Yahang Zheng,
  • Chaosheng Song

摘要

The ultrasonic surface rolling process (USRP) represents a novel approach to surface strengthening. It is employed to enhance components' fatigue life and wear resistance by introducing residual compressive stress and inducing work hardening in the surface layer of the workpiece. The traditional planar USRP exhibits low processing efficiency. To address this, an eccentric planar ultrasonic surface rolling device has been proposed to improve the aforementioned process. A theoretical model of residual stress on the surface of the workpiece is established and numerically simulated by MATLAB, based on Hertzian contact theory and elastic-plasticity theory. Experiments are conducted to investigate the behavior of a plane rolling on a TC4 titanium alloy. This study aims to investigate the influence of machining parameters, including ultrasonic amplitude, feed rate, spindle speed, and rolling depth, on surface residual stress and hardness. The results demonstrate that the USRP can elevate the residual compressive stress on the surface of the workpiece by 5–18.5%, with the residual compressive stress reaching as high as − 639.08 MPa. Furthermore, the average enhancement rate of the surface hardness of the workpiece is 8.9%, with the surface hardness of the workpiece reaching up to 489.7 HV, in comparison to that of the conventional surface rolling process (CSRP). The discrepancy between the theoretical residual stress value and the actual value is 3.7–13.1%, which validates the precision of the model.