A deep rolling finite element analysis procedure for automotive crankshafts

Deep rolling is performed on crankshafts since the 1960s, yet there is still a knowledge gap regarding residual stress generation. Until this moment, there is no consolidated and widespread procedure to predict such stresses during the crankshaft design cycle. This study establishes an analysis proc...

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Bibliographic Details
Published in:Journal of strain analysis for engineering design 2018-04, Vol.53 (3), p.178-188
Main Authors: Fonseca, Luiz GA, de Faria, Alfredo R
Format: Article
Language:English
Subjects:
Boundary element method
Computer simulation
Consolidation
Coordinate measuring machines
Correlation analysis
Crankshafts
Finite element method
Mathematical analysis
Mathematical models
Model accuracy
Residual stress
Studies
X-ray diffraction
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Summary:Deep rolling is performed on crankshafts since the 1960s, yet there is still a knowledge gap regarding residual stress generation. Until this moment, there is no consolidated and widespread procedure to predict such stresses during the crankshaft design cycle. This study establishes an analysis procedure and correlates it with experimental results. An explicit finite element model with real boundary conditions is developed together with a converged mesh for the fillet radius. Simulation nodal displacement and strain output are compared to geometrical measurements using a coordinate-measuring machine. Outputs in terms of residual stresses are related to X-ray diffraction measurements taken along fillet depth. The experimental results attest to the accuracy of the model and correctness in predicting the process outcomes.
ISSN:0309-3247
2041-3130
DOI:10.1177/0309324717751942