Experiment and simulation of the effect of ultrasonic rolling on the surface properties of Ti-6Al-4V

In order to study the effects of ultrasonic rolling pressure on the surface characteristics of titanium alloy Ti-6AL-4V (TC4), a theoretical model of ultrasonic rolling pressure and residual stress was established on the basis of Hertz theory. The effect of different ultrasonic rolling pressures on residual stress was simulated by ABAQUS software. Compared with the ultrasonic rolling TC4 tests, the variation trend of the simulation results closely matched results obtained from physical testing. That is, when other processing parameters were constant, the surface residual stress first increased and then decreased with the increase of the rolling pressure, and the residual stress value was the largest at a rolling pressure of 600 N. The physical tests showed that the surface roughness reached a minimum when the rolling pressure was 600 N, and after it had exceeded 800 N, the surface was damaged and cracks appeared. This showed that the ultrasonic rolling pressure process parameters could achieve good processing effects within a certain range, but adverse effects were generated if this range was exceeded.