This paper describes a new model for predicting micro-pattern deformation in rolling-based surface texturing. With the assumption that the micro-rolling process is essentially quasi-static at relatively low speeds, the model was deduced from the Hertzian theory-based approach of Johnson et al. and experiment data. In particular, to address uncertain factors in micro-rolling contact, a transformation coefficient γ was proposed in the static model to shift from an indentation to a rolling process and was investigated empirically. However, deformation of micro-patterns in rolling contact includes both elastic and plastic phases; thus, an appropriate combination of theoretical and empirical analyses of micro-elastic-plastic deformation was used to establish the static model. A surface deformation constant, ε, was used in an analytical model of elastic-plastic behavior to determine the relationship between the plastic deformation of steady patterns and contact depth. The constant ε was investigated and calculated from experiments and the theoretical model. Subsequent experimental results confirmed the feasibility of the model and demonstrated an incremental plastic proportion, and correspondingly, a decremental elastic proportion when increasing the rolling force. Finally, an elastoplastic ratio, ε e, is presented for estimating elastic and plastic portions distinctly. A nearly linear relationship between ε and ε e was found in this research.
The International Journal of Advanced Manufacturing Technology – Springer Journals
Published: Apr 11, 2017
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