Prozessmodell zum Einbringen von Eigenspannungen durch Festwalzen

Maierhofer, Jürgen; Gänser, Hans-Peter; Pippan, Reinhard

doi:10.1002/mawe.201400276

Cited by 6 publications

(2 citation statements)

References 2 publications

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“…2 shows a sketch of the process steps. After the grinding (1) within the V-groove, tensile residual stresses are introduced, which lead to a deformation of the workpiece after unclamping it from a magnetic clamping plate (2). A proven effective and easily reproducible way to compensate for the distortion is deep rolling (3).…”

Section: Theoretical Approachmentioning

confidence: 99%

“…In this way, compressive load stresses can be introduced in a targeted manner to achieve the desired workpiece geometry. Deep rolling is a proven process for increasing the service life of components and has an increasing importance in industry [2], but it is also a promising process for distortion compensation, as shown in several experiments [3].…”

Section: Introductionmentioning

confidence: 99%

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Modeling of Deep Rolling as a Distortion Compensation Strategy during Profile Grinding

Schieber

Hettig

Zaeh

et al. 2022

KEM

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This paper analyzes the possibility to induce residual compressive stresses utilizing deep rolling in a long, slim steel workpiece that is profile ground and that resembles a linear guide rail. These intentionally caused residual compressive stresses at the side surfaces of the workpiece are intended to counteract the distortion due to residual stresses in the V-groove of the guide rail induced by grinding. A finite element model was prepared based on the initial state of the workpiece. The amount of respective stresses depended on the load intensity and duration of the process. The experimental data regarding the residual stress profiles due to the deep rolling process and the resulting workpiece distortion were used to validate the simulation, so that an adjustment or a calibration of the thermometallurgical and thermomechanical material data was possible. The key findings are the numerical design of appropriate strategies for the distortion potential induction, the experimental distortion results, knowledge on the mechanical treatment by deep rolling, and the successful modeling of the mechanical treatment and the process strategy.

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Section: Theoretical Approachmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Modeling of Deep Rolling as a Distortion Compensation Strategy during Profile Grinding

Schieber

Hettig

Zaeh

et al. 2022

KEM

View full text Add to dashboard Cite

show abstract

Experimental and numerical investigation of the deep rolling process focussing on 34CrNiMo6 railway axles

et al. 2023

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Deep rolling is a powerful tool to increase the service life or reduce the weight of railway axles. Three fatigue-resistant increasing effects are achieved in one treatment: lower surface roughness, strain hardening and compressive residual stresses near the surface. In this work, all measurable changes introduced by the deep rolling process are investigated. A partly deep-rolled railway axle made of high strength steel material 34CrNiMo6 is investigated experimentally. Microstructure analyses, hardness-, roughness-, FWHM- and residual stress measurements are performed. By the microstructure analyses a very local grain distortion, in the range < 5 µm, is proven in the deep rolled section. Stable hardness values, but increased strain hardening is detected by means of FWHM and the surface roughness is significantly reduced by the process application. Residual stresses were measured using the XRD and HD methods. Similar surface values are proven, but the determined depth profiles deviate. Residual stress measurements have generally limitations when measuring in depth, but especially their distribution is significant for increasing the durability of steel materials. Therefore, a numerical deep rolling simulation model is additionally built. Based on uniaxial tensile and cyclic test results, examined on specimen machined from the edge layer of the railway axle, an elastic–plastic Chaboche material model is parameterised. The material model is added to the simulation model and so the introduced residual stresses can be simulated. The comparison of the simulated residual stress in-depth profile, considering the electrochemical removal, shows good agreement to the measurement results. The so validated simulation model is able to determine the prevailing residual stress state near the surface after deep rolling the railway axle. Maximum compressive residual stresses up to about -1,000 MPa near the surface are achieved. The change from the induced compressive to the compensating tensile residual stress range occurs at a depth of 3.5 mm and maximum tensile residual stresses of + 100 MPa at a depth of 4 mm are introduced. In summary, the presented experimental and numerical results demonstrate the modifications induced by the deep rolling process application on a railway axle and lay the foundation for a further optimisation of the deep rolling process.

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