Deep cold rolling simulation of AISI 4140 steel using ANSYS LSDYNA

Krishna Kumar, P and Adhikari, Raviraj and Prabhu, P R and Keni, Laxmikanth (2014) Deep cold rolling simulation of AISI 4140 steel using ANSYS LSDYNA. In: 3rd World Conference on Applied Sciences, Engineering and Technology, 27-29 September 2014, Kathmandu, Nepal.

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Abstract

Deep Cold Rolling (DCR) is a cost effective mechanical surface enhancement process where one or more rollers/ball rolls over the machined surface under high pressure, plasticizing the material’s top layer. Deep rolling is extensively used in aerospace and automobile industries to enhance the fatigue life of components. In the present work, 2D explicit dynamic analysis to simulate deep cold rolling of shafts is carried out using ANSYS/LS DYNA. Effect of significant parameters (ball diameter, rolling force, surface roughness and no of passes) on compressive residual stress generated and depth of compressive residual stress state inside the work piece surface are studied. AISI 4140 STEEL is chosen for work piece material and Tungsten Carbide for tool material. From the 2D simulations compressive residual stress results data are obtained. It is concluded that rolling force and surface roughness have the most significant effect on the compressive residual stresses and depth of compressive residual stress state. The results of the 2D explicit dynamic simulations are also verified with experimental results and both are in good agreement.

Item Type: Conference or Workshop Item (Paper)
Uncontrolled Keywords: Deep cold rolling, Surface roughness, Compressive Residual stress.
Subjects: Engineering > MIT Manipal > Aeronautical and Automobile
Engineering > MIT Manipal > Mechanical and Manufacturing
Depositing User: MIT Library
Date Deposited: 11 May 2016 16:05
Last Modified: 11 May 2016 16:05
URI: http://eprints.manipal.edu/id/eprint/146042

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