Simulation study of turning-ultrasonic rolling compound processing for 42CrMo steel.

The ultrasonic rolling processing technology has been shown to significantly reduce surface roughness and enhance the residual stress of parts, thereby improving their surface properties and extending their service life. This technology is particularly effective for the precision machining and surface strengthening of ultra-high-strength steel 42CrMo. This study aims to investigate the impact of turning pre-processing on the distribution of residual stress during ultrasonic rolling, a simulation model incorporating turning pre-processing was developed and used to conduct ultrasonic rolling simulation experiments, enabling the analysis of residual stress distribution patterns. Concurrently, ultrasonic rolling strengthening experiments were performed to validate the accuracy of the simulation model. The results confirm that with increasing rotational speed and feed rate, residual stress decreases, whereas with increasing static pressure and amplitude, residual stress increases. The residual stress variation obtained from the simulation of combined turning and ultrasonic rolling closely matched the results of experimental ultrasonic rolling tests. This consistency validates the accuracy of the simulation model. This study offers a novel approach for simulating and experimentally validating ultrasonic rolling processes, particularly for shaft-like parts that undergo turning as a pre-processing step.