Modifying the surface topography of tribological interfaces has the potential to improve the friction performance of certain mechanical components that experience sliding contact. Vibromechanical texturing (VMT), an improved texturing method based on the convenient turning process, is introduced. This process is performed on a standard computer numeric controlled (CNC) lathe, which is retrofitted with a piezoelectric-actuated tool positioning stage. Controlled vibratory motion of the tool is used to cut microsized dimples into the surface of the workpiece. Two types of workpiece materials are used: aluminum and hardened steel, with three forms of workpiece geometries: outer cylinder, inner cylinder, and flat/end face. The accuracy of the texturing method is compared with a basic surface topography model, which predicts texture dimensions within an 11% error for aluminum and up to 90% error for hardened steel, using the current open-loop control system. Further analysis of the textured samples shows no significant signs of process-induced damage. It is demonstrated that this VMT method is a versatile, accurate technique that has potential to be a cost-effective means for surface texturing of tribological components.

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Surface hardening techniques are widely used to improve the rolling contact fatigue (RCF) resistance of materials. This study investigated the RCF resistance of hardened, ground steel rods made from three different aircraft-quality alloy steels (AISI 8620, 9310, and 4140) and hardened using different techniques (atmosphere carburizing, vacuum carburizing, and induction hardening) at different case depths. The RCF life of the rods was determined using a three ball-on-rod rolling contact fatigue test machine. After testing, the microstructures of the rods were examined using metallographic techniques. The stress distributions and plastic deformation zones for the specimens under RCF were calculated using an elastoplastic model for plastically graded materials. Relationships between surface hardness, case depth, and RCF life were investigated. The longest lives were observed for the vacuum-carburized AISI 9310 specimens, and the shortest lives were observed for the induction-hardened AISI 4140 specimens. It is concluded that the most important factors in determining the RCF lives of high-cleanliness surface-hardened alloy steels are (1) the hardness in the region of highest octahedral shear stress (in this case, ∼0.13 mm beneath the surface) and (2) the depth of high hardness (>613 HV), which determines the plastic deformation zone size.

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