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