Surface Improvement of Shafts by Turn-Assisted Deep Cold Rolling Process

Prabhu, Raghavendra; Sharma, Sathyashankara; Jagannath, K; Kumar, Krishna; Kulkarni, S. M.

doi:10.1051/matecconf/20167710006

Cited by 4 publications

(3 citation statements)

References 4 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Though they were cost-effective when compared with the former, obvious limitations like friction, degrees of freedom at the tool tip, vibrations especially at higher rolling loads, and pressure variations during rolling resulted in inconsistent modification of material properties. P. R. Prabhu et al [153] proposed two tool designs with mechanical loading mechanisms involving springs (Figure 8a) and threaded shanks (Figure 8b) for the DR of steel material. From their work, it is evident that despite the obvious advantages like better control over the rolling force and the absorption of shock with the spring mechanism for the tool, it was unable to withstand high rolling loads because of limitations with spring stiffness.…”

Section: Deep Rolling Toolsmentioning

confidence: 99%

Deep Rolling Techniques: A Comprehensive Review of Process Parameters and Impacts on the Material Properties of Commercial Steels

Noronha,

Sharma,

Prabhu Parkala

et al. 2024

Metals

View full text Add to dashboard Cite

The proposed review demonstrates the effect of the surface modification process, specifically, deep rolling, on the material surface/near-surface properties of commercial steels. The present research examines the various process parameters involved in deep rolling and their effects on the material properties of AISI 1040 steel. Key parameters such as the rolling force, feed rate, number of passes, and roller geometry are analyzed in detail, considering their influence on residual stress distribution, surface hardness, and microstructural alterations. Additionally, the impact of deep rolling on the fatigue life, wear resistance, and corrosion behavior of AISI 1040 steel is discussed. Engineering components manufactured by AISI 1040 steel can perform better and last longer when deep rolling treatments are optimized with an understanding of how process variables and material responses interact. This review provides critical insights for researchers and practitioners interested in harnessing deep rolling techniques to enhance the mechanical strength and durability of steel components across diverse industrial settings. In summary, the valuable insights provided by this review pave the way for continued advancements in deep rolling techniques, ultimately contributing to the development of more durable, reliable, and high-performance steel components in diverse industrial applications. The establishment of generalized standardizations for the deep rolling process proves unfeasible because of the multitude of controlling parameters and their intricate interactions. Thus, specific optimization studies tailored to the material of interest are imperative for process standardization. The published literature on the characterization of surface and subsurface properties of deep-rolled AISI 1040 steel, as well as process parameter optimization, remains limited. Additionally, numerical, analytical, and statistical studies and the role of ANN are limited compared with experimental work on the deep rolling process.

show abstract

Section: Deep Rolling Toolsmentioning

confidence: 99%

Deep Rolling Techniques: A Comprehensive Review of Process Parameters and Impacts on the Material Properties of Commercial Steels

Noronha,

Sharma,

Prabhu Parkala

et al. 2024

Metals

View full text Add to dashboard Cite

show abstract

“…One of the MSE methods, deep cold rolling (DCR), is getting attention nowadays as it is a fast, chipless, and economical surface enhancement method applicable to prevailing conventional or computer numerical control (CNC) machine tools. Further producing a deep layer of compression and nanocrystalline microstructure on the surface of samples, it also can lessen the surface roughness of materials and enhance the fatigue life of engineering components without affecting their bulk properties (Ref [22][23][24][25][26][27][28][29][30][31][32][33][34]. There are numerous parameters to be considered, and the effects of each of these parameters are dependent on other variables.…”

Section: Introductionmentioning

confidence: 99%

Surface Properties and Corrosion Behavior of Turn-Assisted Deep-Cold-Rolled AISI 4140 Steel

Prabhu

Sharma

et al. 2020

J. of Materi Eng and Perform

Self Cite

View full text Add to dashboard Cite

In this research, the effect of various turn-assisted deep-cold-rolling process parameters on the residual stress, microstructure, surface hardness, surface finish, and corrosion behavior of AISI 4140 steel has been investigated. The examination of the surface morphology of the turned and processed samples was performed by using a scanning electron microscope, energy-dispersive spectroscopy, and atomic force microscopy. Response surface methodology and desirability function approach were used for reducing the number of experiments and finding local optimized conditions for parameters under the study. The results from the residual stress measurements indicate that the rolling force has the highest effect by generating a deeper layer of residual compressive stress. The outcomes of surface hardness and surface finish emphasize that rolling force and number of tool passes are the most significant parameters affecting the responses. Surface studies confirmed the corrosion and its intensity onto the metal surface, and according to atomic force microscopy studies, the surface had become remarkably rough after exposure to the corrosive medium. Improvements in surface microhardness from 225 to 305.8 HV, the surface finish from 4.84 down to 0.261 μm, and corrosion rate from 6.672 down to 3.516 mpy are observed for a specific set of parameters by turn-assisted deep-cold-rolling process. The multiresponse optimization for surface finish and corrosion rate together shows that a ball diameter of 10 mm, a rolling force of 325.75 N, initial roughness of 4.84 µm, and number of tool passes of 3 give better values for the two responses under consideration with composite desirability of 0.9939. Based on the experimental work at the optimum parameter setting, the absolute average error between the experimental and predicted values for the corrosion rate is calculated as 3.2%.

show abstract

“…Prabhu et al proved that this effect of increasing pressure goes beyond the surface, increasing the maximum RS, depth of maximum RS and the Compressive -Tensile Cross-Over (CTCO) of AISI 1060 specimens [90].…”

Section: Pressure/ Force 2211mentioning

confidence: 99%

Analysis and prediction of residual stress in deep cold rolling of Ti-6Al-4V

Lim¹

View full text Add to dashboard Cite

Deep Cold Rolling (DCR) is a mechanical surface treatment method that has been proven to enhance fatigue life of components by inducing deep compressive residual stress (RS), increasing surface hardness and improving surface roughness.This work analyzes the effect of DCR on RS and coupled with the finite element (FE) modelling, deepens the understanding of the mechanics of how DCR imparts the RS into the component, especially at the subsurface region. A three-zone RS profile hypothesis is developed and proven through the use of microstructure and hardness analysis.An analytical model is also developed to predict the RS profile based on the key performance variable inputs. This allows designers and engineers a quick method of developing a starting point for experimentation.The knowledge gained is applied to thin aerofoil-foil like specimens and a technique for achieving a compressive RS zone away from the treated region is proposed.

show abstract

Surface Improvement of Shafts by Turn-Assisted Deep Cold Rolling Process

Cited by 4 publications

References 4 publications

Deep Rolling Techniques: A Comprehensive Review of Process Parameters and Impacts on the Material Properties of Commercial Steels

Deep Rolling Techniques: A Comprehensive Review of Process Parameters and Impacts on the Material Properties of Commercial Steels

Surface Properties and Corrosion Behavior of Turn-Assisted Deep-Cold-Rolled AISI 4140 Steel

Analysis and prediction of residual stress in deep cold rolling of Ti-6Al-4V

Contact Info

Product

Resources

About