Analytic roughness prediction by deep rolling

Deep rolling is a widely applied mechanical surface and subsurface treatment method. It is typically used after conventional machining to improve the roughness, increase the surface hardness and to induce compressive residual stresses. The main influence parameters on the surface topography are the applied deep rolling pressure, the ball diameter and the feed. In general, low feeds, larger ball diameters and higher pressures result in an even surface finish. However, an exact prediction of the roughness is not possible. Therefore, it is the aim of the presented research to find a generally applicable method for surface roughness prediction after deep rolling for a variety of steel and aluminum materials. It is shown that the surface topography can be predicted by an analytical model with high accuracy.