In this paper, the effects of roller geometry on contact pressure and residual stress in crankshaft fillet rolling are investigated by a two-dimensional finite element analysis. The fillet rolling process is first introduced to review some characteristics of the rolling tools. A two-dimensional plane strain finite element analysis is then employed to qualitatively investigate the influence of the roller geometry. Computations have been conducted for eight different contact geometries between the primary roller and the secondary roller to investigate the geometry effect on the contact pressure distribution on the edge of the primary roller. Fatigue parameters of the primary rollers are also estimated based on the Findley fatigue theory. Then, computations have been conducted for three different contact geometries between the primary roller and the crankshaft fillet to investigate the geometry effect on the residual stress distribution near the crankshaft fillet. The results suggest that the contact geometry between the two rollers has significant influence on the contact pressure distribution and the maximum contact pressure along the edge of the primary roller and, consequently, the fatigue lives of the primary rollers. The results also suggest that the contact geometry between the primary roller and the crankshaft fillet does not have significant influence on the overall residual stress distribution and, consequently, may not have significant influence on the fatigue performance of crankshaft sections under bending loads. Therefore, an appropriate adjustment of the contact geometry between the two rollers can significantly improve the fatigue lives of the primary rollers without a significant change of the overall residual stress distributions near the crankshaft fillet and, in turn, the fatigue performance of crankshaft sections under bending loads.


    Access

    Check access

    Check availability in my library

    Order at Subito €


    Export, share and cite



    Title :

    Effects of Roller Geometry on Contact Pressure and Residual Stress in Crankshaft Fillet Rolling


    Additional title:

    Sae Technical Papers


    Contributors:
    Pan, J. (author) / Choi, K. S. (author) / Ho, S. (author)

    Conference:

    SAE 2005 World Congress & Exhibition ; 2005



    Publication date :

    2005-04-11




    Type of media :

    Conference paper


    Type of material :

    Print


    Language :

    English




    Effects of roller geometry on contact pressure and residual stress in crankshaft fillet rolling

    Choi,K.S. / Pan,J. / Ho,S. et al. | Automotive engineering | 2005


    2005-01-1908 Effects of Roller Geometry on Contact Pressure and Residual Stress in Crankshaft Fillet Rolling

    Choi, K. S. / Pan, J. / Ho, S. et al. | British Library Conference Proceedings | 2005


    Potentials of Crankshaft Fillet Rolling Process

    Cevik, M.C. / Hochbein, H. / Rebbert, M. et al. | British Library Conference Proceedings | 2012


    Potentials of Crankshaft Fillet Rolling Process

    Hochbein, Helmut / Cevik, M. Cagri / Rebbert, Martin | SAE Technical Papers | 2012