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<p>This study addresses the complex characterization of depth-dependent variations in hardness and residual stress in ultrasonic rolling process (USRP) titanium alloys by developing a 3D dynamic finite element (FE) model that incorporates actual tool-workpiece kinematics. Systematic simulations reveal critical influences of various parameters on the distribution of residual stress, supplemented by analyses of surface roughness and hardness evolution. Results demonstrate that residual compressive stress (RCS) exhibits a tri-phasic depth profile: it increases to a maximum at a depth of 0.2&#xa0;mm, decays to a neutral state at 0.4&#xa0;mm, and transitions to tensile stress, peaking at 0.6&#xa0;mm before diminishing. Parametric analysis identifies static pressure as the dominant factor, showing a strong linear correlation (R²=0.96) between maximum RCS and pressure increments (0.2-0.6&#xa0;MPa). Experimental validation confirms the accuracy of the model, with less than 10% deviation between simulated and measured stresses. Surface roughness simulations align closely with profilometry data, while the distribution of equivalent plastic strain (PEEQ) strongly correlates with microhardness profiles, establishing PEEQ as a reliable predictor of work-hardening behavior. The FE model effectively captures multi-parameter interactions and subsurface deformation mechanisms, providing a valuable tool for optimizing USRP parameters in titanium alloy surface enhancement applications.</p> Graphical Abstract <p></p>

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Effect of Ultrasonic Surface Rolling Parameters on Titanium Alloy Surface Integrity: A Numerical and Experimental Study of Residual Stress, Hardness, and Roughness

  • 期刊论文

  • 发表日期：

    2025年11月4日

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  • Kaikui Zheng,
  • Yuanteng Li,
  • Xinzhe Zhao,
  • Gang Mou

摘要

This study addresses the complex characterization of depth-dependent variations in hardness and residual stress in ultrasonic rolling process (USRP) titanium alloys by developing a 3D dynamic finite element (FE) model that incorporates actual tool-workpiece kinematics. Systematic simulations reveal critical influences of various parameters on the distribution of residual stress, supplemented by analyses of surface roughness and hardness evolution. Results demonstrate that residual compressive stress (RCS) exhibits a tri-phasic depth profile: it increases to a maximum at a depth of 0.2 mm, decays to a neutral state at 0.4 mm, and transitions to tensile stress, peaking at 0.6 mm before diminishing. Parametric analysis identifies static pressure as the dominant factor, showing a strong linear correlation (R²=0.96) between maximum RCS and pressure increments (0.2-0.6 MPa). Experimental validation confirms the accuracy of the model, with less than 10% deviation between simulated and measured stresses. Surface roughness simulations align closely with profilometry data, while the distribution of equivalent plastic strain (PEEQ) strongly correlates with microhardness profiles, establishing PEEQ as a reliable predictor of work-hardening behavior. The FE model effectively captures multi-parameter interactions and subsurface deformation mechanisms, providing a valuable tool for optimizing USRP parameters in titanium alloy surface enhancement applications.

Graphical Abstract