Authors: S. Zaides, T. Le

Title of the article: Effect of the tool working profile geometry on the stress-strain state of parts during line surface plastic deformation

Year: 2026, Issue: 4, Pages: 17-32

Branch of knowledge: 2.5.6. Engineering technology

Index UDK: 621.787.4

DOI: 10.26730/1999-4125-2026-4-17-32

Abstract: Fatigue resistance in high-duty cylindrical components is fundamentally dictated by the integrity of their surface layer properties. Multi-pass line surface plastic deformation (SPD) serves as a robust technique for surface modification. However, a recurring limitation of this process is the edge effect, inherent to standard cylindrical rollers, where localized stress concentrations trigger non-uniform material flow. This phenomenon inevitably results in residual surface pile-ups at track boundaries, thereby degrading product quality. This study establishes a physical and mathematical framework for optimizing tool profile geometry to mitigate such macro-geometric defects during high-precision multi-pass SPD. The underlying contact mechanics were analyzed using a 3D elastoplastic finite element model developed in ANSYS Workbench. The numerical simulation addressed the hardening of AISI 1045 (steel 45) specimens subjected to four distinct tool configurations: a basic cylindrical profile, a 45° chamfered tool, an undercut profile, and a modified radial-transition roller. The evolution of the stress-strain state within the deformation zone was evaluated throughout the active loading phase and subsequent complete system unloading. Findings corroborate that the roller profile serves as the primary determinant for the lateral material displacement mechanism. It is demonstrated that a modified profile with a geometrically optimized radial transition facilitates a "controlled confinement" mechanism for plastic flow. This design strategy successfully overcomes the trade-off between the depth of hardening and the surface defect height. The application of this modified tool yields axial compressive residual stresses of up to 330 MPa, while reducing track-boundary micro-pileup height to 2–3 μm—an improvement of nearly an order of magnitude over conventional tooling. Furthermore, an optimal circular feed limit of 2.5 mm was substantiated, allowing for a substantial increase in processing throughput without compromising the structural integrity of the generated microrelief.

Key words: line surface plastic deformation cylindrical parts roller profile residual stresses plastic flow edge effect finite element modeling

Receiving date: 12.05.2026

Approval date: 01.09.2026

Publication date: 10.09.2026

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