TY - GEN
T1 - Finite element simulation of roller burnishing in crankshafts
AU - Courtin, S.
AU - Henaff-Gardin, C.
AU - Bezine, G.
PY - 2003/12/1
Y1 - 2003/12/1
N2 - Roller burnishing is a very commonly used industrial process. It involves a local plastic deformation on surfaces that permits the fatigue strength of structures to be increased. Crack propagation is indeed delayed by the introduction of compressive residual stresses. In this way, this process is particularly useful in the presence of stress concentrators like in the fillets of crankshafts or in notched shafts for instance. In the present work, a three-dimensional finite element analysis is carried out with the commercial software ABAQUS in order to model roller burnishing in the fillets of crankshafts. The contact between the workpiece and the tool is simulated and the latter is subjected to a pressure. Thus, all the residual stresses and strains can be calculated after unloading. The outputs are compared to experimental profiles of residual stresses measured by X-ray diffraction and a good agreement between experimental and three-dimensional numerical results is obtained. Unfortunately, this analysis is costly and the effects of roller burnishing can only be observed in the vicinity of the contact between the tool and the piece and not on the whole circumference of the shaft since neither the tool nor the piece rotates. However, our investigations show also that a simple axisymmetric model may approach experiments, not considering residual stresses as unknown quantities but as inputs of the problem. The three-dimensional field obtained by revolving the two-dimensional one will then make it possible to study, by the finite element method, crack propagation in such residual stress fields.
AB - Roller burnishing is a very commonly used industrial process. It involves a local plastic deformation on surfaces that permits the fatigue strength of structures to be increased. Crack propagation is indeed delayed by the introduction of compressive residual stresses. In this way, this process is particularly useful in the presence of stress concentrators like in the fillets of crankshafts or in notched shafts for instance. In the present work, a three-dimensional finite element analysis is carried out with the commercial software ABAQUS in order to model roller burnishing in the fillets of crankshafts. The contact between the workpiece and the tool is simulated and the latter is subjected to a pressure. Thus, all the residual stresses and strains can be calculated after unloading. The outputs are compared to experimental profiles of residual stresses measured by X-ray diffraction and a good agreement between experimental and three-dimensional numerical results is obtained. Unfortunately, this analysis is costly and the effects of roller burnishing can only be observed in the vicinity of the contact between the tool and the piece and not on the whole circumference of the shaft since neither the tool nor the piece rotates. However, our investigations show also that a simple axisymmetric model may approach experiments, not considering residual stresses as unknown quantities but as inputs of the problem. The three-dimensional field obtained by revolving the two-dimensional one will then make it possible to study, by the finite element method, crack propagation in such residual stress fields.
M3 - Conference contribution
AN - SCOPUS:3042644105
SN - 1853129623
T3 - Computational and Experimental Methods
SP - 333
EP - 342
BT - Surface Treatment VI
A2 - Brebbia, C.A.
A2 - Hosson, J.T.M.
A2 - Nishida, S.-I.
T2 - Sixth International Conference on Computer Methods and Experimental Measurements for Surface Treatment Effects, Surface Treatment VI
Y2 - 11 March 2003 through 13 March 2003
ER -