Fatigue Failure of Rollers in Crankshaft Fillet Rolling

Choi, Kyoo Sil; Pan, Jwo; Ho, Simon

doi:10.4271/2004-01-1498

Cited by 8 publications

(6 citation statements)

References 15 publications

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“…Elastic behavior follows Hooke's Law. equation 1shows the relation between stress s and elastic strain e el through Young's modulus E. ''Cast Iron Plasticity'' flow rule models the plastic behavior after yielding as in equation (2). The plastic strain e pl is defined to be normal to the flow potential G and proportional to the hardening parameter l. Tensile and compressive plastic behavior follows isotropic hardening model and flow rule.…”

Section: Materials Modelmentioning

confidence: 99%

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A deep rolling finite element analysis procedure for automotive crankshafts

Fonseca

Faria

2018

The Journal of Strain Analysis for Engineering Design

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Deep rolling is performed on crankshafts since the 1960s, yet there is still a knowledge gap regarding residual stress generation. Until this moment, there is no consolidated and widespread procedure to predict such stresses during the crankshaft design cycle. This study establishes an analysis procedure and correlates it with experimental results. An explicit finite element model with real boundary conditions is developed together with a converged mesh for the fillet radius. Simulation nodal displacement and strain output are compared to geometrical measurements using a coordinatemeasuring machine. Outputs in terms of residual stresses are related to X-ray diffraction measurements taken along fillet depth. The experimental results attest to the accuracy of the model and correctness in predicting the process outcomes.

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Section: Materials Modelmentioning

confidence: 99%

“…Choi et al 2,3 focused on roller fatigue and influence of roller geometry over crankshaft fillet residual stress generation using a two-dimensional finite element model. The simulations were used to qualitatively investigate the influence of the primary roller geometry on contact pressure distribution and stress field in the contact area.…”

Section: Introductionmentioning

confidence: 99%

A deep rolling finite element analysis procedure for automotive crankshafts

Fonseca

Faria

2018

The Journal of Strain Analysis for Engineering Design

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“…Crankshaft deep rolling numerical models and simulations still lack a direct correlation with the fatigue behaviour of the component. [18][19][20][21][22][23] Çevik 24 and Spiteri et al 25 both developed a three-dimensional model for the process. The latter also incorporated bending moment simulations to their research.…”

Section: Introductionmentioning

confidence: 99%

“…Crankshaft deep rolling numerical models and simulations still lack a direct correlation with the fatigue behaviour of the component . Çevik and Spiteri et al .…”

Section: Introductionmentioning

confidence: 99%

Numerical modelling of deep rolling influence over crankshaft bending and correlation with fatigue behaviour

Fonseca

Cantisano

Faria

2019

Fatigue Fract Eng Mat Struct

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The requirements for mechanical reliability of automotive crankshafts are continuously increasing, thus pushing the demand for an optimized processing. Nonetheless, the manufacturing‐induced residual stresses at critical sites for fatigue enhancement are not clarified in the state‐of‐the‐art on the topic. In particular, there is a lack of information on the effect of final manufacturing stages to improve the component life endurance, such as deep rolling, in the overall stress state while the component is under operational loads. This study deepens the validation of a finite element deep rolling model under development with the aid of an in‐house developed crankshaft resonance fatigue test rig. The stress state obtained from the deep rolling simulation was input as a predefined stress field for the simulation of operational conditions experimented at the test rig. Test results produced cracks at the fillet radii of the cast iron crankshafts as anticipated. Overlapping the fractography with the simulation's final stress field yielded interesting correlation with the crack morphology. This contributed with a strong indication of the model correctness. Moreover, it can be further implemented to indicate whether the process parameters such as roller force and angle are fully optimized for each particular crankshaft application.

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“…In automotive industries, fatigue damage has occurred near the crankshaft fillets due to the stress concentration. Deep rolling has been applied to the crankshaft or shaft fillets to enhance the fatigue strengths of crankshafts [2][3][4]. In aerospace industries, the initiation and early growth of fatigue cracks, especially in the presence of foreign-object damage, in the turbine engine components is one of the most critical challenges.…”

Section: Introductionmentioning

confidence: 99%

Finite Element Analysis of Residual Stress in Ti-6Al-4V Alloy Plate Induced by Deep Rolling Process under Complex Roller Path

Liou¹,

El-Wardany²

2014

International Journal of Manufacturing Engineering

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The kinematics of the deep rolling tool, contact stress, and induced residual stress in the near-surface material of a flat Ti-6Al-4V alloy plate are numerically investigated. The deep rolling tool is under multiaxis nonlinear motion in the process. Unlike available deep rolling simulations in the open literature, the roller motion investigated in this study includes penetrative and slightly translational motions. A three-dimensional finite element model with dynamic explicit technique is developed to simulate the instantaneous complex roller motions during the deep rolling process. The initial motion of the rollers followed by the penetration motion to apply the load and perform the deep rolling process, the load releasing, and material recovery steps is sequentially simulated. This model is able to capture the transient characteristics of the kinematics on the roller and contacts between the roller and the plate due to variations of roller motion. The predictions show that the magnitude of roller reaction force in the penetration direction starts to decrease with time when the roller motion changes to the deep rolling step and the residual stress distributions in the near-surface material after the material recovery step varies considerably along the roller path.

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Fatigue Failure of Rollers in Crankshaft Fillet Rolling

Cited by 8 publications

References 15 publications

A deep rolling finite element analysis procedure for automotive crankshafts

A deep rolling finite element analysis procedure for automotive crankshafts

Numerical modelling of deep rolling influence over crankshaft bending and correlation with fatigue behaviour

Finite Element Analysis of Residual Stress in Ti-6Al-4V Alloy Plate Induced by Deep Rolling Process under Complex Roller Path

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