Skip to main content
SpringerLink
Log in

Finite element and experimental study of the residual stresses in 2024-T3 Al alloy treated via single toroidal roller burnishing

  • Technical Paper
  • Published:
Journal of the Brazilian Society of Mechanical Sciences and Engineering Aims and scope Submit manuscript

Abstract

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.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8

Similar content being viewed by others

Abbreviations

A 5 :

Elongation

A :

Amplitude

B :

Amplitude

C :

Kinematic hardening modulus

D :

External diameter of the toroidal deforming roller

d :

Workpiece diameter

\(d_{\text{p}}\) :

Depth of penetration

E :

Young’s modulus

f :

Feed rate

\(F_{\text{b}}\) :

Burnishing force

n :

Number of passes

N :

Number of cycles to failure

r :

Radius of the toroid of the toroidal deforming roller

R :

Cycle asymmetry coefficient

\(t_{\text{step}}\) :

One cycle time

\(v\) :

Burnishing velocity

\(\alpha_{ij}\) :

Back-stress tensor

\(\bar{\varepsilon }_{\text{p}}\) :

Equivalent plastic strain

\(\phi\) :

Roller rotation angle

\(\gamma\) :

Rate of decrease in C

\(\nu\) :

Poisson’s ratio

\(\theta (\theta_{0} )\) :

Central angles of the workpiece modeled portion

\(\sigma^{0}\) :

Equivalent stress

\(\sigma_{\text{a}}\) :

Stress amplitude

\(\sigma_{ij}\) :

Stress tensor

\(\sigma_{ - 1}\) :

Fatigue limit for symmetrical cycle

\(\sigma_{\text{u}}\) :

Ultimate stress

\(\sigma_{\text{Y}}\) :

Yield limit

\(\sigma_{\text{t}}^{\text{res}}\) :

Residual hoop stress

\(\sigma_{\text{z}}^{\text{res}}\) :

Residual axial stress

\(\omega\) :

Angular velocity

\(\psi\) :

Transverse contraction

CNC:

Computer numerical control

DR:

Deep rolling

FE:

Finite element

HBB:

Hydrostatic ball burnishing

LPB:

Low plasticity burnishing

MST:

Mechanical surface treatment

RB:

Roller burnishing

SB:

Slide burnishing

SRB:

Single roller burnishing

STRB:

Single toroidal roller burnishing

References

  1. Maximov JT, Duncheva GV, Anchev AP, Ichkova MD (2019) Slide burnishing—review and prospects. Int J Adv Manuf Technol 104:785–801

    Article  Google Scholar 

  2. Catalogue E (2006) Tools and solutions for metal surface improvement. Ecoroll Corporation Tool Technology USA

  3. Maximov JT, Anchev AP, Dunchev VP, Ganev N, Duncheva GV, Selimov KF (2017) Effect of slide burnishing basic parametrers on fatigue performance of 2024-T3 high-strength aluminium alloy. Fatigue Fract Eng Mater Struct 40(11):1893–1904

    Article  Google Scholar 

  4. Maximov JT, Anchev AP, Duncheva GV, Ganev N, Selimov KF, Dunchev VP (2019) Impact of slide diamond burnishing additional parameters on fatigue behaviour of 2024-T3 Al alloy. Fatigue Fract Eng Mater Struct 42(1):363–373

    Article  Google Scholar 

  5. Borkar AP, Kamble PS, Seemikeri CY (2014) Surface integrity enhancement of inconel 718 by using roller burnishing process. Int J Curr Eng Technol 4(4):2595–2598

    Google Scholar 

  6. Hassani-Gangaraj S, Carboni M, Gnagliano M (2015) Finite element approach toward an advanced understanding of deep rolling induced residual stresses, and an application to railway axles. Mater Des 83:689–703

    Article  Google Scholar 

  7. Dwivedi SP, Sharma S, Mishra RK (2014) Effects of roller burnishing process parameters on surface roughness of A356/5%SiC composite using response surface methodology. Adv Manuf 2:303–317

    Article  Google Scholar 

  8. Perenda J, Trajkovski J, Zerovnik A, Prebil I (2015) Residual stresses after deep rolling of a torsion bar made from high strength steel. J Mater Process Technol 218:89–98

    Article  Google Scholar 

  9. Abrão AM, Denkena B, Köhler J, Breidenstein B, Mörke T (2014) The influence of deep rolling on the surface integrity of AISI 1060 high carbon steel. Proc CIRP 13:31–36

    Article  Google Scholar 

  10. Chomienne V, Valiorgue F, Rech J, Verdu C (2016) Influence of ball burnishing on residual stress profile of a 15-5PH stainless steel. CIRP J Manuf Sci Technol 13:90–96

    Article  Google Scholar 

  11. Yuan X, Sun Y, Li C, Liu W (2017) Experimental investigation into the effect of low plasticity burnishing parameters on the surface integrity of TA2. Int J Adv Manuf Technol 88:1089–1099

    Article  Google Scholar 

  12. Zhang P, Lindemann J, Ding WJ, Leyens C (2010) Effect of roller burnishing on fatigue properties of the hot-rolled Mg–12Gd–3Y magnesium alloy. Mater Chem Phys 124:835–840

    Article  Google Scholar 

  13. Fouad Y, Mhaede M, Wagner L (2010) Effect of mechanical surface treatment on fatigue performance of extruded ZK60 alloy. Fatigue Fract Eng Mater Struct 34:403–407

    Article  Google Scholar 

  14. Wagner L, Mhaede M, Wollmann M, Altenberger I, Sano Y (2011) Surface layer properties and fatigue behavior in Al 7075-T73 and Ti–6Al–4V. Comparing results after laser peening, shot peening and ball-burnishing. Int J Struct Integr 2(2):185–199

    Article  Google Scholar 

  15. Yen YC, Sartkulvanich P, Altan T (2005) Finite element modeling of roller burnishing process. CIRP Ann Manuf Technol 54(1):237–240

    Article  Google Scholar 

  16. Sartkulvanich P, Altan T, Jasso F, Rodriguez C (2007) Finite element modeling of hard roller burnishing: an analysis on the effects of process parameters upon surface finish and residual stresses. J Manuf Sci Eng 129(4):705–716

    Article  Google Scholar 

  17. Maximov JT, Anchev AP, Duncheva GV, Ganev N, Selimov KF (2017) Influence of the process parameters on the surface roughness, micro-hardness, and residual stresses in slide burnishing of high-strength aluminum alloys. J Braz Soc Mech Sci Eng 39(8):3067–3078

    Article  Google Scholar 

  18. Maximov JT, Duncheva GV, Anchev AP, Ganev N, Amudjev IM, Dunchev VP (2018) Effect of slide burnishing method on the surface integrity of AISI 316Ti chromium–nickel steel. J Braz Soc Mech Sci Eng 40:194. https://doi.org/10.1007/s40430-018-1135-3

    Article  Google Scholar 

  19. Maximov JT, Duncheva GV, Anchev AP, Ganev N, Dunchev VP (2019) Effect of cyclic hardening on fatigue performance of slide burnished components made of low-alloy medium carbon steel. Fatigue Fract Eng Mater Struct 42(6):1414–1425

    Article  Google Scholar 

  20. Maximov JT, Duncheva GV, Anchev AP (2019) A temperature-dependent, non-linear kinematic/isotropic hardening material constitutive model of the surface layer of 37Cr4 steel subjected to slide burnishing. Arab J Sci Eng 44(6):5851–5862

    Article  Google Scholar 

  21. Bougharriou A, Saï WB, Saï K (2010) Prediction of surface characteristics obtained by burnishing. Int J Adv Manuf Technol 51:205–215

    Article  Google Scholar 

  22. Salahshoor M, Guo YB (2011) Finite element modeling of burnishing and the effects of process parameters on surface integrity of orthopedic implants. In: Proceedings of the ASME 2011 international mechanical engineering congress and exposition IMECE2011, November 11–17, Denver, Colorado, USA

  23. Sayahi M, Sghaier S, Belhadjsalah H (2013) Finite element analysis of ball burnishing process: comparisons between numerical results and experiments. Int J Adv Manuf Technol 67:5–8

    Article  Google Scholar 

  24. Hassanifard S, Mousavi M, Varvani-Farahani A (2018) The influence of low-plasticity burnishing process on the fatigue life of friction-stir-processed Al7075-T6 samples. Fatigue Fract Eng Mater Struct 42(3):764–772

    Article  Google Scholar 

  25. Mohammadi F, Sedaghati R, Bonakdar A (2014) Finite element analysis and design optimization of low plasticity burnishing process. Int J Adv Manuf Technol 70:1337–1354

    Article  Google Scholar 

  26. Zhuang W, Wicks B (2004) Multipass low-plasticity burnishing induced residual stresses: three-dimensional elastic–plastic finite element modeling. Proc Inst Mech Eng Part C J Mech Eng Sci 218(6):663–668

    Article  Google Scholar 

  27. Aldrine ME, Mahendra Babu NC, Anil Kumara S (2017) Evaluation of induced residual stresses due to low plasticity burnishing through finite element simulation. Mater Today Proc 4:10850–10857

    Article  Google Scholar 

  28. Balland P, Tabourot L, Degre F, Moreau V (2013) An investigation of the mechanics of roller burnishing through finite element simulation and experiments. Int J Mach Tool Manuf 65:29–36

    Article  Google Scholar 

  29. Beghini M, Bertini L, Monelli BD, Santus S, Bandini M (2014) Experimental parameter sensitivity analysis of residual stresses induced by deep rolling on 7075-T6 aluminium alloy. Surf Coat Technol 254:175–186

    Article  Google Scholar 

  30. Duncheva GV, Atanasov TP (2020) Finite element modeling and optimization of the deep rolling process with a torodal roller in aluminum alloy 2024 T3. J Tech Univ Gabrovo 60:3–14

    Google Scholar 

  31. Maximov JT, Duncheva GV, Anchev AP, Ichkova MD (2014) Modeling of strain hardening and creep behaviour of 2024-T3 aluminium alloy at room and high temperatures. Comput Mater Sci 83:381–393

    Article  Google Scholar 

  32. Ganev N, Frydrýšek K, Kolařík K (2007) Possibilities of FEM for verification of X-ray measurement of residual stresses depth distribution. In: Book of extended abstracts. 9th international scientific conference applied mechanics 2007. Technical University of Ostrava, Malenovice, April 16–19, 2007, pp 85–86, ISBN 978-80-248-1389-9

Download references

Acknowledgements

This work was supported by the European Regional Development Fund within the OP “Science and Education for Smart Growth 2014–2020”, Project CoC “Smart Mechatronics, Eco- and Energy Saving Systems and Technologies”, No. BG05M2OP001-1.002-0023.

Author information

Authors and Affiliations

  1. Technical University of Gabrovo, 5300, Gabrovo, Bulgaria

    G. V. Duncheva, J. T. Maximov, A. P. Anchev, V. P. Dunchev & T. P. Atanasov

  2. Czech Technical University in Prague, Prague, Czech Republic

    Jiri Capek

Authors
  1. G. V. Duncheva
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. J. T. Maximov
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. A. P. Anchev
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. V. P. Dunchev
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. T. P. Atanasov
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Jiri Capek
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to G. V. Duncheva.

Additional information

Technical Editor: Lincoln Cardoso Brandao.

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Duncheva, G.V., Maximov, J.T., Anchev, A.P. et al. Finite element and experimental study of the residual stresses in 2024-T3 Al alloy treated via single toroidal roller burnishing. J Braz. Soc. Mech. Sci. Eng. 43, 55 (2021). https://doi.org/10.1007/s40430-020-02775-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s40430-020-02775-8

Keywords

Search

Navigation