Abstract
An effective approach to increasing the fatigue resistance of metal products is to create residual compressive stresses on the surface of the product using surface plastic deformation (SPD) processing SPD. In the present study, with the help of the finite element analysis, one of the effective SPD methods, the process of abrasive-free ultrasonic finishing (AFUF), is studied. Another well-known approach to improving mechanical characteristics, including the fatigue resistance, is the creation of an ultrafine-grained (UFG) structural state in the product. This study is devoted to investigation of the stress–strain state of a UFG workpiece subjected to SPD by the AFUF method using the finite element analysis. Commercially pure Grade 4 titanium in the UFG state obtained by the equal channel angular pressing “conform” method (ECAP-C) is chosen as the workpiece material. In the course of the study, the stress–strain state of the deformation zone after a single impact of an indenter with subsequent unloading is analyzed in the elastoplastic formulation of the problem. The effect of the oscillation amplitude and geometrical characteristics of the indenter on residual radial stresses, including their depth of occurrence, average normal stress, and the accumulated effective strain, has been analyzed. It has been established that, with an increase in the indenter radius, the value of the accumulated effective strain (e) decreases. The behavior of distribution of the e parameter shows a gradient character with its values decreasing from the surface to the center of the workpiece. An analysis of the simulation results shows that the residual radial stresses in the region of the deformation zone are predominantly compressive stresses and, accordingly, allow increasing the fatigue resistance of the final product. It has been established that, with an increase in the indenter oscillation amplitude, the values of residual radial stresses also rise, with their maximum achieving 540 MPa at the amplitude of 75 µm and the depth of occurrence of these stresses reaching 0.3 mm. Increasing the indenter radius, or, in other words, in fact, the contact surface area, leads to an increase in the residual radial compressive stresses, which turns out to be an almost linear increase.
Similar content being viewed by others
REFERENCES
Terent’ev, V.F., Ustalost’ metallicheskikh materialov (Fatigue of Metal Materials), Moscow: Nauka, 2002.
Brunette, D.M., Tengvall, P., Textor, M., and Thomsen, P., Titanium in Medicine, Berlin, Heidelberg: Springer, 2001.
Elias, C.N., Lima, J.H.C., Valiev, R., and Meyers, M.A., Biomedical applications of titanium and its alloys, JOM, 2008, vol. 60, pp. 46–49. https://doi.org/10.1007/s11837-008-0031-1
Lowe, T. and Valiev, R.Z., Investigations and Applications of Severe Plastic Deformation, NATO Science Partnership Subseries: 3, Springer Science & Business Media, 2000.
Zehetbauer, M.J. and Valiev, R.Z., Nanomaterials by Severe Plastic Deformation, John Wiley and Sons, 2006.
Segal, V.M., Materials processing by simple shear, Mater. Sci. Eng., A, 1995, vol. 197, pp. 157–164.
Erdedi, A.A., Medvedev, Yu.A., and Erdedi, N.A., Tekhnicheskaya mekhanika: Teoreticheskaya mekhanika. Soprotivlenie materialov (Technical Mechanics: Theoretical Mechanics. Strength of Materials), Moscow: Vysshaya Shkola, 1991.
Pande, C.S., Imam, M.A., and Srivatsan, T.S., Fundamentals of fatigue crackinitiation and propagation: A review, in Fatigue of Materials: Advances and Emergences in Understanding, TMS (The Minerals, Metals & Materials Society), 2010, pp. 1–18.
Li, L., Kim, M., Lee, S., Bae, M., and Lee, D., Influence of multiple ultrasonic impact treatments on surface roughness and wear performance of SUS301 steel, Surf. Coat. Technol., 2016, vol. 307, pp. 517–524.
Liu, C.S., Liu, D.X., Zhang, X.H., Liu, D., Ma, A.M., Ao, N., and Xu, X.C., Improving fatigue performance of Ti–6Al–4V alloy via ultrasonic surface rolling process, J. Mater. Sci. Technol., 2019, vol. 35, pp. 1555–1562.
Fedchishin, O.V., Trofimov, V.V., and Klimenov, V.A., Effect of ultrasonic treatment on the structure and physical and mechanical properties of titanium VT1-0, Sib. Med. Zh., 2009, no. 6, pp. 189–192.
Zhang, H., Chiang, R., Qin, H.F., Ren, Z.C., Hou, X.N., Lin, D., Doll, G.L., Vasudevan, V.K., Dong, Y.L., and Ye, C., The effects of ultrasonic nanocrystal surface modification on the fatigue performance of 3D-printed Ti64, Int. J. Fatigue, 2017, vol. 103, pp. 136–146.
Liu, J., Suslov, S., Ren, Z.C., Dong, Y.L., and Ye, C., Microstructure evolution in Ti64 subjected to laser-assisted ultrasonic nanocrystal surface modification, Int. J. Mach. Tools Manuf., 2019, vol. 136, pp. 19–33.
Kholopov, Yu.V., Non-abrasive ultrasonic finishing of metals—technology of the 21st century, Metalloobrabotka, 2002, no. 4, pp. 46–48.
Aleksandrov, M.K., Papsheva, N.D., and Akushskaya, O.M., Ultrasonic hardening of GTD parts, Bull. Samara State Aerosp. Univ., 2011, no. 3, no. 27, pp. 271–276.
Kozlov, E.V., Gromov, V.E., Kovalenko, V.V., and Popova, N.A., Gradientnye struktury v perlitnoi stali (Gradient Structures in Pearlitic Steel), Novokuznetsk: Siberian State Industrial Univ., 2004.
Ivanov, Yu.F., Efimov, O.Yu., Popova, N.A., Kovalenko, V.V., Konovalov, S.V., Gromov, V.E., and Kozlov, E.V., Formation of gradient structural-phase states at the nanoscale level in rolling rolls, Fundam. Probl. Sovrem. Materialoved., 2008, no. 4, pp. 55–58.
Lu, K., Making strong nanomaterials ductile with gradients, Science, 2014, vol. 345, pp. 1455–1456.
Kattoura, M., Telang, A., Mannava, S.R., Qian, D., and Vasudevan, V.K., Effect of ultrasonic nanocrystal surface modification on residual stress, microstructure and fatigue behavior of ATI 718Plus alloy, Mater. Sci. Eng., A., 2018, vol. 711, pp. 364–377.
Liu, D., Liu, D.X., Zhang, X.H., Liu, C.S., and Ao, N., Surface nanocrystallization of 17-4 precipitation-hardening stainless steel subjected to ultrasonic surface rolling process, Mater. Sci. Eng., A., 2018, vol. 726, pp. 69–81.
Müller, M., Lebedev, A., Svobodová, J., Náprsková, N., and Lebedev, P., Abrasive-free ultrasonic finishing of metals, Manuf. Technol., 2014, vol. 14, no. 3, pp. 366–370.
Aleš, Z., Pavlů, J., Hromasová, M., and Svobodová, J., Tribological properties of brass surfaces machined by abrasive—free ultrasonic finishing process, Manuf. Technol., 2019, vol. 19, no. 1, pp. 3–8.
Klimenov, V.A., Kovalevskaya, Zh.G., Kaminskii, P.P., Sharkeev, Yu.P., and Lotkov, A.I., Ultrasonic surface treatment—a promising way to increase the service life of railway transport parts, Bull. Dahl Natl. Res. Univ., 2010, vol. 152, no. 10, pp. 117–121.
Kovalevskaya, Zh.G., Ivanov, Yu.F., Perevalova, O.B., Klimenov, V.A., and Uvarkin, P.V., Study of microstructure of surface layers of low-carbon steel after turning and ultrasonic finishing, Phys. Met. Metallogr., 2013, vol. 114, no. 1, pp. 41–53.
Chao Guo, Wang Zhijiang, Wang Dongpo, and Hu Shengsun, Numerical analysis of the residual stress in ultrasonic impact treatment process with single-impact and two-impact models, Appl. Surf. Sci., 2015, vol. 347, pp. 596–601.
Gunderov, D.V., Polyakov, A.V., Churakova, A.A., Semenova, I.P., Raab, G.I., Valiev, R.Z., Gemaletdinova, E., Sabirov, I., Segurado, J., Sitdikov, V.D., Alexandrov, I.V., and Enikeev, N.A., Evolution of microstructure, macrotexture and mechanical properties of commercially pure Ti during ECAP-Conform, Mater. Sci. Eng, A., 2013, vol. 562, pp. 128–136. https://doi.org/10.1016/j.msea.2012.11.007
Sibum, H., Güther, V., Roidl, O., Habashi, F., Uwe, H., Wolf, H., and Siemers, C., Titanium, titanium alloys, and titanium compounds, in Ullmann’s Encyclopedia of Industrial Chemistry, Wiley-VCH, 2017, pp. 1–35.
Meier, L., Schaal, N., and Wegener, K., In-process measurement of the coefficient of friction on titanium, Procedia CIRP, 2017, vol. 58, pp. 163–168.
Morikage, Y., Igi, S., Oi, K., Jo, Y., Murakami, K., and Gotoh, K., Effect of compressive residual stress on fatigue crack propagation, Procedia Eng., 2015, vol. 130, pp. 1057–1065.
Kodama, S., Misawa, H., and Ohsumi, K., Compressive residual stress on fatigue fractured surface, in International Conference on Residual Stresses, Dordrecht: Springer, 1989.
Funding
This study was performed through a grant of the Russian Science Foundation, no. 21-79-00124, https://rscf.ru/project/21-79-00124/.
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
The authors declare that they have no conflict of interest.
Additional information
Translated by Z. Smirnova
About this article
Cite this article
Asfandiyarov, R.N., Raab, G.I., Gunderov, D.V. et al. Finite Element Analysis of the Stress–Strain State of the Deformation Zone of a Workpiece from UFG Grade 4 Ti Subjected to Abrasive-Free Ultrasonic Finishing. Russ. J. Non-ferrous Metals 63, 617–623 (2022). https://doi.org/10.3103/S1067821222060037
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.3103/S1067821222060037