Crankshaft deep rolling analysis through energy balance simulation output

Abstract

The residual stresses generated during the deep rolling process made on crankshafts are still not fully understood to this day. Comprehending and correctly simulating the process dynamics are key to investigate the process influence over the material microstructure. A numerical model using an explicit formulation was developed in order to accurately simulate deep rolling dynamics. Real boundary conditions, contact and a converged mesh were set. Diverse mass scaling and load rate were tested for comparison. The results were evaluated in terms of the simulation energy balance, as the internal, kinetic and artificial energies outputs were confronted. Conclusions could be inferred on the accuracy of the model representation of the real process based on this analysis.