Theoretical and numerical investigation of micro-textures fabrication by ultrasonic surface rolling process

Surface texturing is a potential approach to achieving excellent surface performance. To realize high precision and efficiency in micro-texturing fabrication, method utilizing an ultrasonic rolling process proposed. Firstly, the feasibility geometric controllability of micro-texture preparation using are analyzed. Then, contact theory model established, which can describe relationship generation region. Based on elastic–plastic theory, simulations single-pass multi-pass processes developed elucidate formation strengthening mechanism micro-textures, further characterize effects machining parameters micro-textures. A series validation tests implemented AISI 5140 steel. Simulation experimental results show that fabricate micro-groove arrays with periodic distribution. The validity theoretical finite element models confirmed by comparison results. It demonstrated feasible efficient way controllable