An Experimental Investigation on the Effect of Deep cold Rolling Parameters on Surface Roughness and Hardness of AISI 4140 Steel
Deep cold rolling (DCR) is a cold working process, which easily produces a smooth and work-hardened surface by plastic deformation of surface irregularities. In the present study, the influence of main deep cold rolling process parameters on the surface roughness and the hardness of AISI 4140 steel were studied by using fractional factorial design of experiments. The assessment of the surface integrity aspects on work material was done, in terms of identifying the predominant factor amongst the selected parameters, their order of significance and setting the levels of the factors for minimizing surface roughness and/or maximizing surface hardness. It was found that the ball diameter, rolling force, initial surface roughness and number of tool passes are the most pronounced parameters, which have great effects on the work piece-s surface during the deep cold rolling process. A simple, inexpensive and newly developed DCR tool, with interchangeable collet for using different ball diameters, was used throughout the experimental work presented in this paper.
Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1077383Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1846
 I. Altenberger, B. Scholtes, "Improvement of fatigue lifetime of mechanically surface treated materials in the low cycle fatigue regime", Surface Treatment IV (Eds. Kenny J., Brebbia S.). Southampton, WIT press, p. 281, 1999.
 M. H. El-Axir, O. M. Othman, A. M. Abodiena, "Improvements in outof- roundness and microhardness of inner surfaces by internal ball burnishing process", Journal of Materials Processing Technology, Vol 196, pp 120-128, 2008.
 A. Tolga Bozdana, R. K. Nalla, "On the influence of mechanical surface treatments (deep rolling and laser shock peening) on the fatigue behaviour of Ti-6Al-4V at ambient and elevated temperatures", Materials Science and Engineering A355, pp 216-230, 2003.
 Kwai S. Chan, Michael P. Enright, Jonathan P. Moody, Patrick J. Golden, Ramesh Chandra, Alan C. Pentz, "Residual stress profiles for mitigating fretting fatigue in gas turbine engine disks", International Journal of Fatigue, Vol. 32, pp 815-823, 2010.
 I. Altenberger, "Deep rolling - the past, the present and the future", 9th International conference on shot peening. September 6-9, Paris, Marne la Vallee, France, 2005.
 K. H. Kloos, B. Fuchsbauer, J. Adelmann, "Fatigue properties of specimens similar to components deep rolled under optimized conditions", International journal of fatigue 9, No. 1, pp 35-42, 1987.
 P. Juijerm, U. Noster, I. Altenberger, B. Scholtes, "Fatigue of deep rolled AlMg4.5Mn (AA5083) in the temperature range 20-3000C", Materials Science and Engineering A 379, pp 286-292, 2004.
 B. Scholtes, "Assessment of residual stresses, Structural and residual stress analysis by non-destructive methods", V. Hauk, Ed., Elsevier, Amsterdam, pp 590-632, 1997.
 David K. Matlock, Khaled A. Alogab, Mark D. Richards, John G. Speer, "Surface Processing to Improve the Fatigue Resistance of Advanced Bar Steels for Automotive Applications", Materials Research, Vol. 8, No. 4, pp 453-459, 2005.
 H. Luo, J. Liu, L. Wang, Q. Zhong, "The effect of burnishing parameters on burnishing force and surface micro hardness", International Journal of Advanced Manufacturing Technology, Vol 28, pp 707-713, 2006.
 Douglas C. Montgomery, "Design and Analysis of Experiments", sixth edition, John Wiley & sons, Inc., 2005.