Research Papers

Effect of Deep Cold Rolling on Residual Stress Distributions Between the Treated and Untreated Regions on Ti–6Al–4V Alloy

[+] Author and Article Information
Andre Lim

Computer Aided Engineering
Lab 1 (N3–B3b–05),
School of Mechanical and
Aerospace Engineering,
Nanyang Technological University,
50 Nanyang Avenue,
Singapore 639798, Singapore;
Advanced Technology Centre,
Rolls-Royce Singapore Pte. Ltd,
Singapore 797575, Singapore
e-mail: lims0200@e.ntu.edu.sg

Sylvie Castagne

School of Mechanical and
Aerospace Engineering,
Nanyang Technological University,
50 Nanyang Avenue,
Singapore 639798, Singapore
e-mail: scastagne@ntu.edu.sg

Chow Cher Wong

Advanced Technology Centre,
Rolls-Royce Singapore Pte. Ltd,
6 Seletar Aerospace Rise,
Singapore 797575, Singapore
e-mail: chow.wong@rolls-royce.com

1Corresponding author.

Manuscript received July 24, 2015; final manuscript received March 3, 2016; published online June 23, 2016. Assoc. Editor: Gracious Ngaile.

J. Manuf. Sci. Eng 138(11), 111005 (Jun 23, 2016) (8 pages) Paper No: MANU-15-1371; doi: 10.1115/1.4033524 History: Received July 24, 2015; Revised March 03, 2016

The residual stress distributions caused by the deep cold rolling (DCR) process, with a focus on the distributions at the boundary of the treatment zone, are examined in this study. A three-dimensional finite-element (FE) model, validated with experimental residual stress data, is used to study the effect of the process. The residual stress distribution in the crosswise direction (perpendicular to rolling direction) shows a region of tensile residual stress at the start and end of the track that may be a cause for concern. The reason for this region of tensile stress is likely to be due to the reduced treatment of the start and end zones due to the step over and the tool path taken. Other factors that cause a difference between the steady state and the transient zone of the burnished area are also investigated. It is shown that the net material movement causes larger plastic deformation in the boundary zone between the burnished and unburnished region of DCR.

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Fig. 2

Experimental determination of track width

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Fig. 1

DCR experimental setup

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Fig. 5

Operating principle of the DCR tool, including stroke and force calculations

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Fig. 6

Schematic of tool path

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Fig. 3

Compression strain-hardening curve for Ti–6Al–4V

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Fig. 9

Reduced number of passes at initial and end zones due to the nature of tool path

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Fig. 10

Displacement with material flow symbols (top) and plastic strain (bottom) in the crosswise (y) direction

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Fig. 11

Interaction between burnishing tracks

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Fig. 12

Lengthwise residual stress distribution

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Fig. 13

Close up view of zone A, showing higher compressive residual stress relative to the surrounding area

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Fig. 14

Displacement (top) and plastic strain (bottom) in the lengthwise (x) direction

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Fig. 7

Experimental—FE comparison of normalized residual stress profile at the center of the test coupon

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Fig. 8

Crosswise residual stress distribution



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