Authors: S.E. Uchaikin, V.Yu. Blumenstein

Title of the article: Development of a method for assessing a deformation site formed during roller rolls on complex-profile surfaces

Year: 2025, Issue: 3, Pages: 59-71

Branch of knowledge: 2.5.6. Engineering technology

Index UDK: 621.787

DOI: 10.26730/1999-4125-2025-3-59-71

Abstract: A technique has been developed for estimating the deformation zone (DZ), determining the geometric parameters and calculating the accumulated degree of shear deformation in different areas of a complex-profile surface during roller rolling. Structural elements such as keyways and splines, fillet transitions between steps, grooves, threads, etc., are stress concentrators that negatively affect the performance properties of parts. In most cases, shafts are subject to cyclic alternating loads, so ensuring the required cyclic durability or increasing it is an urgent task. The analysis showed that one of the available methods that does not require expensive equipment and tooling is the method of surface plastic deformation (SPD) by roller rolling. In the opinion of the authors, identifying the regularities of the stationarity of metal flow in the surface layer (SL) during roller rolling of complex-profile surfaces will help solve this problem. In preparation for the main experiments on studying the deformation center transformation in different areas of a complex-profile surface during rolling with rollers, a debugging experiment was performed, which considered methods for estimating the geometric parameters of the deformation zone (axial and altitude) and calculating the accumulated degree of shear deformation. To calculate the latter, it was proposed to use a known model in which the geometric parameters of the deformation center are unknown. To determine the horizontal and vertical parameters of the deformation center, 2 methods were proposed that showed similar results. The results of calculating the accumulated degree of shear deformation are comparable with the results of other authors, which indicates the possibility of using the developed technique.

Key words: complex profile shafts surface plastic deformation rolling deformation zone degree of shear deformation

Receiving date: 04.04.2025

Approval date: 10.06.2025

Publication date: 26.06.2025

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