Theoretical and numerical investigation of micro-textures fabrication by ultrasonic surface rolling process

Abstract

Surface texturing is a potential approach to achieving excellent surface performance. To realize high precision and efficiency in micro-texturing fabrication, a surface texturing method utilizing an ultrasonic surface rolling process is proposed.Firstly, the feasibility and geometric controllability of micro-texture preparation using ultrasonic surface rolling process are analyzed. Then a contact theory model of ultrasonic rolling texturing process is established, which can describe the geometric relationship of the micro-texturing generation region. Based on the elastic-plastic theory, simulations of single-pass and multi-pass ultrasonic rolling texturing processes are developed to elucidate the formation and strengthening mechanism of micro-textures, and further characterize the effects of ultrasonic rolling machining parameters on micro-textures. A series of validation tests of ultrasonic rolling texturing are implemented on AISI 5140 steel. Simulation and experimental resultsshow that the ultrasonic surface rolling process can fabricate micro-groove arrays with the periodic distribution. The validity of the theoretical and finite element models is confirmed by the comparison results. It is demonstrated that the ultrasonic rolling texturing process is a feasible and efficient way to fabricate controllable micro-textures.

Experimental study on surface roughness processed by ultrasonic surface rolling process

“…Wu et al [5] investigated the friction properties of GCr15 with varying textures after USRP processing and found that the friction reduction performance under the cross-texture shape was the best. Meng et al [6] simulated and experimented with USRP on 5140 steel and found that USRP can prepare textures on the surface of parts. The parts processed by USRP have significantly improved the residual stress [7], microhardness [8], microstructure [9], mechanical properties [10], and so on.…”