Surface micro-morphology and residual stress formation mechanisms of near-net-shaped blade produced by low-plasticity ultrasonic rolling strengthening process

Wu, Dongbo; Lv, Hongru; Wang, Hui; Yu, Jie

doi:10.1016/j.matdes.2022.110513

Cited by 27 publications

(7 citation statements)

References 13 publications

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“…Seeger et al [10] considered that the first kind of stress is a constant in the macroscopic range, and the second kind of stress is also a constant in the microscopic domain, which tends to change periodically in the macroscopic range as well as the third kind of stress in the microscopic domain. Given the preparation and treatment of metallic materials, such as drawing [11], extrusion [12], rolling [13], corroding [14], cutting [15], grinding [16], surface rolling [17], shot peening [18], hammering [19], casting [20], quenching heat treatment [21], welding [22], etc., these four types of residual stresses are inevitable.…”

Section: Introductionmentioning

confidence: 99%

Mechanism of Electropulsing Treatment Technology for Flow Stress of Metal Material: A Review

Lu,

Tang,

et al. 2024

Alloys

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Residual stress is caused by non–uniform deformation caused by non–uniform force, heat and composition, which is of great significance in engineering applications. It is assumed that the residual stress is always the upper limit of the elastic limit, so the reduction of the flow stress will reduce the residual elastic stress. It is particularly important to control the flow stress in metal materials. Compared with traditional methods, the use of electropulsing treatment (EPT) technology stands out due to its energy–efficient, highly effective, straightforward and pollution–free characteristics. However, there are different opinions about the mechanism of reducing flow stress through EPT due to the conflation of the effects from pulsed currents. Herein, a clear correlation is identified between induced stress levels and the application of pulsed electrical current. It was found that the decrease in flow stress is positively correlated with the current density and the duration of electrical contact and current action time. We first systematically and comprehensively summarize the influence mechanisms of EPT on dislocations, phase, textures and recrystallization. An analysis of Joule heating, electron wind effect, and thermal–induced stress within metal frameworks under the influence of pulsed currents was conducted. And the distribution of electric, thermal and stress fields under EPT are discussed in detail based on a finite element simulation (FES). Finally, some new insights into the issues and challenges of flow stress drops caused by EPT are proposed, which is critically important for advancing related mechanism research and the revision of theories and models.

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Section: Introductionmentioning

confidence: 99%

Mechanism of Electropulsing Treatment Technology for Flow Stress of Metal Material: A Review

Lu,

Tang,

et al. 2024

Alloys

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“…Wen et al [33] constructed a thermal-mechanical coupling UVAG residual stress prediction model through the finite element method, studied the formation rules of UVAG residual stress, and found that the introduction of ultrasonic vibration can reduce the occurrence of surface tensile stress. Wu et al [34] proposed a finite element analysis method for a low plasticity ultrasonic rolling strengthening process, analyzing the Influence of ultrasonic rolling parameters on surface residual stress. The research results indicated that the workpiece surface formed a residual compressive stress layer of approximately 70 𝜇m through ultrasonic rolling, and the residual stress increased before decreasing with the depth.…”

Section: Introductionmentioning

confidence: 99%

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Ye,

Jun,

Tang

et al. 2024

Preprint

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Ultrasonic vibration-assisted grinding (UVAG) technology has advantages in improving part surface integrity. Currently, the calculation of residual stresses in UVAG typically relies on commercial finite element software. However, because commercial finite element software is not specialized for residual stress calculations, the computational efficiency could be higher, and the accuracy could be better. This paper proposes a semi-analytical residual stress prediction model that considers the Influence of ultrasonic vibration. This paper introduces a semi-analytical residual stress prediction model that considers the impact of ultrasonic vibration. The model calculates the grinding mechanical and thermal stress fields separately using contact mechanics and finite difference methods. Based on Hertz's contact theory and Timoshenko's thermoelastic theory, a correlation model is provided for the association between mechanical and thermal loads with the internal stresses in the workpiece. Subsequently, the residual stress field is solved by considering the thermal-mechanical coupling effects in UVAG. Ultrasonic-assisted grinding experiments were conducted using 12Cr2Ni4A alloy steel as the object, and the maximum error between the predicted residual stresses by the model and the measured residual stresses was 10.5%.In addition, the detailed discussion on the Influence of grinding parameters on residual stress reveals that reducing the grinding wheel speed can significantly increase surface compressive residual stress. The paper's research shows that the residual stress distribution obtained by the new residual stress calculation model is correct, and the calculation efficiency is high, providing a new method for predicting residual stress in UVAG.

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“…During the USRP process, ultrasonic vibration caused severe plastic deformation and formed a residual compressive stress layer on the material surface, which inhibited crack expansion. It also refined the surface grains 19 .…”

Section: Introductionmentioning

confidence: 99%

Surface Microstructure Refinement and Mechanical Properties of GCr15 Steels Improved During Ultrasonic Surface Rolling Processing

Xue

et al. 2023

Mat. Res.

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In this paper, ultrasonic surface rolling processing (USRP) was used to strengthen GCr15-bearing steel. A finite element three-dimensional model of USRP was established to analyze the residual compressive stress and equivalent plastic strain distribution on the bearing steel surface. The microstructure, hardness, surface roughness, and corrosion resistance before and after USRP treatment were characterized by SEM, EBSD, X-ray diffraction (XRD), and electrochemical techniques. Results indicated that USRP treatment can significantly improve the material's surface microstructure and residual compressive stress distribution and obtain a plastic strain layer of about 60μm. After USRP treatment, the Kernel Average Misorientation (KAM) increased, and the dislocation activity was more intensive, resulting in aggregation near grain boundaries, and the percentage of LAGBs increased to 38.8%. Under the combined effect of surface grain refinement, residual compressive stress, and high glossy surface, the self-corrosion current density is reduced by two orders of magnitude, and the corrosion resistance is significantly improved. This investigation suggests a solution to the bearing failure problem and has implications for understanding the deformation mechanism of ultrasonic surface rolling processing.

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Surface micro-morphology and residual stress formation mechanisms of near-net-shaped blade produced by low-plasticity ultrasonic rolling strengthening process

Cited by 27 publications

References 13 publications

Mechanism of Electropulsing Treatment Technology for Flow Stress of Metal Material: A Review

Mechanism of Electropulsing Treatment Technology for Flow Stress of Metal Material: A Review

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Surface Microstructure Refinement and Mechanical Properties of GCr15 Steels Improved During Ultrasonic Surface Rolling Processing

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