Analysis of internal material loads and Process Signature Components in deep rolling

The high mechanical loads in deep rolling lead to a beneficial surface topography, hardness alterations, and compressive residual stresses. The generation of defined residual stress values has been achieved in a mainly iterative way, as the relevant internal material loads occurring during the process could not be considered. They are difficult to determine experimentally and well-validated models are required to deduce them e.g. from finite element (FE) simulations. In this study, a 3D FE model has been developed to analyze the strains in the workpiece material as a measure for the internal material load during the process. The residual stress profiles were measured by x-ray-diffraction and are presented in a way that allows for deriving the internal material loads required to induce a desired residual stress state.