The Effect of Tool Geometry and Part Shape on Contact Zone Parameters During Plastic Surface Deformation With Rollers

The influence of the geometric parameters of the deforming rollers and the shape of the workpieces on the characteristics of the contact zone during surface plastic deformation (SPD) is considered. The importance of this work lies in the optimization of SPD processes to improve the efficiency of workpiece machining. Traditional studies often do not establish a direct relationship between the deformation force and the geometry of the tool and the workpiece, which limits the ability to accurately predict the processing results. The article proposes an innovative mathematical model that describes the relationship between the geometry of the rollers and the contact geometry for various types of machined surfaces, including shafts and holes. This model takes into account a variety of shapes and sizes of rollers, as well as the geometry of the workpiece. The key objective of the study is to determine the quantitative relationships between the geometric parameters of the tool and the characteristics of the contact zone. The work analyzes the influence of the roller and workpiece radii, the type of machined surface and the roller penetration depth on the size and shape of the contact zone. Using the developed mathematical model, numerical calculations were performed that clearly demonstrate the results of using a profile roller. It was found that the dimensions of the contact zone depend significantly on the radius of the workpiece, especially when processing parts with small diameters, which must be taken into account when designing technological processes. The publication presents graphs of functional relationships corresponding to various forms of tools and workpieces. In order to verify the accuracy of the developed mathematical model, a comparative analysis of the calculated indicators with the results calculated according to the principles of elasticity theory was performed.