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 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.