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<p>The crankshaft journals of high-power, high-speed diesel engines are subjected to dynamic impact loads generated by extremely high combustion pressures and must transmit heavy load torques. These complex and harsh operating conditions impose stringent requirements on the strength, fatigue strength, corrosion resistance, wear resistance, and long-term service stability of the crankshaft journal surfaces. To overcome the technical challenge of lacking suitable processing equipment for applying ultrasonic rolling strengthening technology on crankshaft journal surfaces, this paper designs and develops a specialized ultrasonic rolling strengthening processing actuator for crankshafts. Using the ANSYS finite element analysis platform, numerical simulation verification of modal characteristics and harmonic response of its core component (the ultrasonic rolling vibrator) was completed, along with multi-objective response surface structural optimization. Firstly, the theoretical design equations of the ultrasonic rolling vibrator were derived using the one-dimensional longitudinal vibration theory of variable cross-section rods and the four-terminal network method, and the structure and dimensions of each component were determined. Secondly, modal and harmonic response simulation verification analysis of the ultrasonic rolling vibrator was conducted based on ANSYS Workbench software. Finally, structural optimization of the ultrasonic rolling vibrator was achieved through a multi-objective response surface optimization method based on a genetic algorithm. The results show that the redesigned and optimized ultrasonic rolling actuator can resonate at the theoretical operating frequency of 39,300&#xa0;Hz and generate a maximum ultrasonic amplitude of approximately 13&#xa0;μm, meeting the requirements for ultrasonic rolling processing. This study starts from theoretical analysis and calculations to obtain the structural dimensions of each part of the ultrasonic rolling vibrator, and combines finite element simulation analysis to achieve structural optimization of the ultrasonic rolling vibrator. This solves the technical problem of ultrasonic rolling strengthening processing on the connecting rod journal surface and provides process technical references for the research, development, and manufacturing of similar critical components.</p>

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Simulation design and structure optimization of the multisegmented composite ultrasonic rolling vibrator for crankshaft journal

  • 期刊论文

  • 发表日期：

    2025年11月25日

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  • Jianli Jia,
  • Yougui Wei,
  • Yajun Wang,
  • Mi Zhang,
  • Mingxuan He,
  • Tengteng Han,
  • Qingxiang Wang

摘要

The crankshaft journals of high-power, high-speed diesel engines are subjected to dynamic impact loads generated by extremely high combustion pressures and must transmit heavy load torques. These complex and harsh operating conditions impose stringent requirements on the strength, fatigue strength, corrosion resistance, wear resistance, and long-term service stability of the crankshaft journal surfaces. To overcome the technical challenge of lacking suitable processing equipment for applying ultrasonic rolling strengthening technology on crankshaft journal surfaces, this paper designs and develops a specialized ultrasonic rolling strengthening processing actuator for crankshafts. Using the ANSYS finite element analysis platform, numerical simulation verification of modal characteristics and harmonic response of its core component (the ultrasonic rolling vibrator) was completed, along with multi-objective response surface structural optimization. Firstly, the theoretical design equations of the ultrasonic rolling vibrator were derived using the one-dimensional longitudinal vibration theory of variable cross-section rods and the four-terminal network method, and the structure and dimensions of each component were determined. Secondly, modal and harmonic response simulation verification analysis of the ultrasonic rolling vibrator was conducted based on ANSYS Workbench software. Finally, structural optimization of the ultrasonic rolling vibrator was achieved through a multi-objective response surface optimization method based on a genetic algorithm. The results show that the redesigned and optimized ultrasonic rolling actuator can resonate at the theoretical operating frequency of 39,300 Hz and generate a maximum ultrasonic amplitude of approximately 13 μm, meeting the requirements for ultrasonic rolling processing. This study starts from theoretical analysis and calculations to obtain the structural dimensions of each part of the ultrasonic rolling vibrator, and combines finite element simulation analysis to achieve structural optimization of the ultrasonic rolling vibrator. This solves the technical problem of ultrasonic rolling strengthening processing on the connecting rod journal surface and provides process technical references for the research, development, and manufacturing of similar critical components.