Table of Contents
International Journal of Manufacturing Engineering
Volume 2014 (2014), Article ID 786354, 14 pages
Research Article

Finite Element Analysis of Residual Stress in Ti-6Al-4V Alloy Plate Induced by Deep Rolling Process under Complex Roller Path

United Technologies Research Center, 411 Silver Lane, East Hartford, CT 06108, USA

Received 29 July 2014; Revised 25 November 2014; Accepted 26 November 2014; Published 24 December 2014

Academic Editor: Archie Lockamy

Copyright © 2014 J. J. Liou and T. I. El-Wardany. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.


The kinematics of the deep rolling tool, contact stress, and induced residual stress in the near-surface material of a flat Ti-6Al-4V alloy plate are numerically investigated. The deep rolling tool is under multiaxis nonlinear motion in the process. Unlike available deep rolling simulations in the open literature, the roller motion investigated in this study includes penetrative and slightly translational motions. A three-dimensional finite element model with dynamic explicit technique is developed to simulate the instantaneous complex roller motions during the deep rolling process. The initial motion of the rollers followed by the penetration motion to apply the load and perform the deep rolling process, the load releasing, and material recovery steps is sequentially simulated. This model is able to capture the transient characteristics of the kinematics on the roller and contacts between the roller and the plate due to variations of roller motion. The predictions show that the magnitude of roller reaction force in the penetration direction starts to decrease with time when the roller motion changes to the deep rolling step and the residual stress distributions in the near-surface material after the material recovery step varies considerably along the roller path.