This article presents the outcomes of finite element (FE) simulations and X-ray stress measurements of residual stresses in high-strength 2024-T3 Al alloy introduced via the single toroidal roller burnishing (STRB) process. In terms of the deforming toroidal roller geometry, STRB is particularly suitable for deep rolling. A 3D FE model was developed using the flow stress concept, and the actual STRB kinematics was simulated to evaluate both hoop and axial residual stresses. The FE model was validated through a comparison of FE and X-ray residual stress distributions. The effects of the burnishing force, feed rate, and number of passes on the residual hoop and axial stresses were studied. It was established that increasing the feed rate leads to a decrease in the residual hoop stresses and an increase in the residual axial stresses. The greater burnishing force increases the compressive zone depth and only slightly increases the surface residual stresses. The FE and X-ray stress analyses confirm the effectiveness of STRB of 2024-T3 Al alloy to introduce significant residual compressive axial and hoop stresses.

本文介绍了通过单环形滚轮抛光（STRB）工艺引入的高强度2024-T3铝合金的有限元（FE）模拟结果和残余应力的X射线应力测量。就环形环形滚子的变形而言，STRB特别适用于深轧。使用流动应力概念开发了3D有限元模型，并模拟了实际的STRB运动学来评估环向和轴向残余应力。通过比较FE和X射线残余应力分布来验证FE模型。研究了抛光力，进给速度和通过次数对残余箍和轴向应力的影响。已经确定，提高进给速度会导致残余环向应力的减少和残余轴向应力的增加。较大的抛光力会增加压缩区的深度，而只会稍微增加表面残余应力。有限元和X射线应力分析证实了2024-T3铝合金的STRB引入明显的残余压缩轴向应力和环向应力的有效性。