Graduate Thesis Or Dissertation
 

Numerical and Analytical Evaluation of Residual Stresses in Deep Rolling

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https://ir.library.oregonstate.edu/concern/graduate_thesis_or_dissertations/sn00b543n

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  • Deep rolling is a surface finishing technique that is widely used in several industries, specifically aerospace and automotive. Extending fatigue life by inducing compressive residual stresses at and below the deep rolled surface has been the primary driving force behind this newfound popularity. Understanding the development of the residual stresses is unfortunately not as well developed as many other surface finishing techniques, which makes the implementation of process costly to new industries not already familiar with the process or its results. Furthermore, experimental measuring of residual stress profiles induced by deep rolling are either destructive to the workpiece, extremely expensive requiring expensive test equipment, or flat out impossible due to component geometry. Therefore, the development of a reliable model is of great value to many industries that already use deep rolling in their processes, as well as new industries looking to implement it. This research uses finite element analysis (FEA) and develops a calibrated analytical model of the deep rolling process to better understand the creation of these residual stresses. FEA of small deep rolling tools at low pressures performed in this research were able to accurately predict both the magnitude and shape of the residual stress profiles induced in deep rolled Al 7050. FEA of larger deep rolling tools at low pressure overestimated residual stress profiles in the deep rolling specimen. A computationally efficient elastic analytical model calibrated by experimental results is proposed in this research for the approximation of residual stresses. The analytical model accurately approximated residual stresses along the axis perpendicular to the deep rolling tools motion at the contact surface for small deep rolling tools at low pressures. Modeling of large deep rolling tools at low deep rolling pressure were less accurate but still a close enough approximation to be a useful tool with residual stresses along the axis perpendicular to the tool travel being underestimated but the residual stress profile being accurately approximated. The magnitude of greatest compressive residual stress was reasonably accurate. Investigations into the validity of the displacement loading used in the finite element models validity on large tools at low pressure as well as into the minimum allowable domain size for deep rolling specimens relative to the deep rolling tool used would improve the accuracy of the finite element models, likely at the cost of computational speed. Investigations into analytically deriving calibrating factors for the calibrated model would allow for a completely analytical model, removing the need for experimental results at given deep rolling parameters.
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