Deep Roll Peening Rollers for Graduated Compressive Stress
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Solution Overview
Problem
Existing deep roll peening processes lack the ability to uniformly and dynamically control the deep rolling force across a workpiece surface, leading to inconsistent residual compressive stresses and mechanical properties.
Innovation Solution
A method and system utilizing multiple groups of opposed rollers with varying force-couplings, cam members, and profiled workpiece engagement surfaces to dynamically control the deep rolling force along a feed path, allowing for non-uniform force distribution and graduated compressive stress profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single roller or simple opposed roller system is used for deep roll peening, then the device complexity is low, but the ability to uniformly and dynamically control deep rolling force across the workpiece surface is insufficient
Solution Approach 1:
The roller system is divided into multiple groups of opposed rollers arranged in series along the feed path. Each group can independently control the deep rolling force, allowing segmented control of compressive stress distribution across different regions of the workpiece surface. This segmentation enables uniform force distribution while maintaining manageable complexity through modular architecture.
Solution Approach 2:
The system incorporates dynamic control mechanisms including cam members with varying profiles and force-couplings that can adjust the deep rolling force exerted by each roller group as a function of workpiece position. This dynamic adjustment capability allows the system to maintain optimal compressive stress uniformity throughout the peening process while adapting to different workpiece geometries and requirements.
2Manufacturing precision
If the deep rolling force is applied uniformly across all roller groups, then the device complexity is low, but the ability to achieve graduated compressive stress profiles is limited
Solution Approach 1:
Each roller group is equipped with its own force-coupling and cam member configuration, enabling localized control of deep rolling force. Different groups can exert different forces tailored to specific regions of the workpiece, creating graduated compressive stress profiles that optimize mechanical properties in different areas while maintaining overall system coherence.
Solution Approach 2:
The system varies the deep rolling force parameter across different roller groups and along the feed path by using cam members with different profiles. This parameter variation enables the creation of graduated compressive stress profiles, transitioning from uniform force application to spatially varying force distribution to achieve desired stress gradients in the workpiece.
3Strength
If opposed rollers are used to exert deep roll peening force, then the mechanical properties and fatigue strength are improved, but the ability to dynamically adjust force along the feed path is insufficient
Solution Approach 1:
The opposed roller groups are equipped with dynamic adjustment mechanisms including cam members and force-couplings that enable real-time variation of deep rolling force as the workpiece moves along the feed path. This dynamic capability allows optimization of compressive stress induction for improved fatigue strength while adapting to different workpiece positions, geometries, and material properties throughout the peening process.
Solution Approach 2:
The system incorporates control mechanisms that can sense workpiece position and adjust the deep rolling force accordingly through the cam members and force-couplings. This feedback-based control ensures optimal force application for maximizing fatigue strength while maintaining adaptability to varying workpiece characteristics along the feed path.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the mechanical properties and fatigue strength of workpieces by achieving uniform and graduated compressive stress profiles across the surface, improving surface characteristics and durability.
Implementation Method 1
contacting the metal surface of the article with a tool or object to plastically deform the surface
Data Source
AI summary
A method for deep roll peening a workpiece includes deep roll peening a workpiece by moving the workpiece along a feed path through multiple groups of opposed rollers that are arranged in series. Each group of opposed rollers includes a rim that defines a workpiece engagement surface that exerts a deep roll peening force on the workpiece. A deep roll peening system includes multiple groups of opposed rollers. Each of the opposed rollers is rotatably mounted and has a rim that defines a workpiece engagement surface. The workpiece engagement surfaces are spaced apart from each other by a gap. The groups are arranged in series such that the gaps define a feed path for receiving a workpiece into serial contact with the workpiece engagement surfaces.