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<p>Ultrasonic surface rolling process is a new surface modification technique that can significantly reduce the roughness of component surfaces while introducing residual compressive stresses, thereby greatly improving the components’ fatigue performance and service life. Due to present technological bottlenecks, this process is primarily applied to simple component geometries such as planes and cylinders. For this reason, this paper combined the principle of gear meshing with Double-roller Gear Ultrasonic Rolling (DGUR) to complete the strengthening of the gear tooth surface and established a DGUR numerical model that considers the initial micro-hardness gradient, the initial stress state, and initial surface topography of the sample gear. Moreover, a series of DGUR experiments with different process parameters were conducted through the DGUR experimental platform. The numerical model of the residual stress distribution on the surface layer of the gear tooth surface shows good agreement with the experimental results and the maximum value of the relative error of the residual stress is only 6.03%, which confirms the efficacy of the numerical model. Based on the model, after DGUR treatment, the residual compressive stress on the tooth surface reached 491.5&#xa0;MPa, with the maximum residual compressive stress reaching 788.1&#xa0;MPa, which is a maximum increase of 483.7% relative to the initial residual compressive stress. Furthermore, the surface roughness <i>Sa</i> at the top of the tooth was reduced from 0.388 to 0.179&#xa0;μm, significantly improving the surface quality of the gear. The significance of this research lies in the successful numerical simulation of DGUR and the establishment of an experimental platform, which has great engineering application value and socio-economic benefits.</p>

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Numerical modeling of residual stress of 40cr gear by double-roller gear ultrasonic rolling

  • 期刊论文

  • 发表日期：

    2025年7月4日

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  • Zhengyu Shi,
  • Wen Shao,
  • Liangliang Lv,
  • Jinyuan Tang,
  • Yu Shi,
  • Xin Li

摘要

Ultrasonic surface rolling process is a new surface modification technique that can significantly reduce the roughness of component surfaces while introducing residual compressive stresses, thereby greatly improving the components’ fatigue performance and service life. Due to present technological bottlenecks, this process is primarily applied to simple component geometries such as planes and cylinders. For this reason, this paper combined the principle of gear meshing with Double-roller Gear Ultrasonic Rolling (DGUR) to complete the strengthening of the gear tooth surface and established a DGUR numerical model that considers the initial micro-hardness gradient, the initial stress state, and initial surface topography of the sample gear. Moreover, a series of DGUR experiments with different process parameters were conducted through the DGUR experimental platform. The numerical model of the residual stress distribution on the surface layer of the gear tooth surface shows good agreement with the experimental results and the maximum value of the relative error of the residual stress is only 6.03%, which confirms the efficacy of the numerical model. Based on the model, after DGUR treatment, the residual compressive stress on the tooth surface reached 491.5 MPa, with the maximum residual compressive stress reaching 788.1 MPa, which is a maximum increase of 483.7% relative to the initial residual compressive stress. Furthermore, the surface roughness Sa at the top of the tooth was reduced from 0.388 to 0.179 μm, significantly improving the surface quality of the gear. The significance of this research lies in the successful numerical simulation of DGUR and the establishment of an experimental platform, which has great engineering application value and socio-economic benefits.