FINITE-ELEMENT MODELING AND OPTIMIZATION OF THE DEEP ROLLING PROCESS WITH A TOROIDAL ROLLER IN ALUMINUM ALLOY 2024-T3
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- TITLE: FINITE-ELEMENT MODELING AND OPTIMIZATION OF THE DEEP ROLLING PROCESS WITH A TOROIDAL ROLLER IN ALUMINUM ALLOY 2024-T3
- ABSTRACT: In this article the deep rolling with toroidal roller of cylindrical specimens made of 2024-T3high- strength aluminum alloy was studied and optimized in terms of the useful residual axial stress distribution. For this purpose, a planned numerical experiment was conducted, based on developed 3D finite element model of the process being studied. The surface layer constitutive model was defined in accordance with the flow stress concept. The governing factors are the radius of roller curvature, the feed rate, and the burnishing force magnitude. The objective functions are the residual axial stresses in the middle of the surface being treated and the average velue of the residual axial stresses in a depth of 0.5 mm from the surface. In order to study the objective functions, dispersion analysis (ANOVA) and regression analysis were performed. Based on the obtained regression models, the process optimization was conducted. As a result, the governing factors values providing the maximum intensive and deep zone with useful residual axial stresses were defined.
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