Hybrid soft machining of AISI 1045 by turn-rolling and its advantages

Abstract A part’s mechanical life span significantly depends on its microstructure, residual stress state and material hardness. Current research shows that the mechanical surface-strengthening process of deep-rolling is a suitable method for the alteration of surface and subsurface properties with the aim of increasing strength and life span of highly stressed components. Further increase in the mechanical life span can be reached using the turning process temperature while deep-rolling. For this purpose, a turn-rolling tool has been developed. Especially concerning soft machining operations, the induced process temperatures lead to higher degrees of plastic deformation in the subsurface of the material. This results in lower surface roughness, higher hardness and an optimal residual stress state. Furthermore, the turn-rolling process leads to positive properties regarding the part’s microstructure because of the increased elastic and plastic deformations in the subsurface thanks to the combination of thermo-mechanical interactions within the material.