Application behavior of a piezo-actuated deep rolling tool

Deep rolling is a conventional machining process used to modify the surface and subsurface properties of components. It entails subjecting a component’s surface to controlled plastic deformation through the application of mechanical forces. This technology is important in various technical fields, as it offers the possibility of improving the mechanical properties and performance of components. In the case of mechanical deep rolling tools, the deep rolling force is modified by altering the roller’s position through displacement of the machine axis. When dealing with the deep rolling of hybrid components consisting of multiple materials, a highly dynamic change of the deep rolling force is required in the material transition zone for adapting the deep rolling force to the different materials. Therefore, a piezo-actuated deep rolling tool was developed to enable a precise and dynamic deflection of the rolling element. The paper focuses on the application behavior of this new tool. For this purpose, the influence of the rolling element’s highly dynamic actuation on rolling force, tool temperature, and surface topography as a function of different material properties were investigated. Within the framework of these investigations, correlations between actuation frequency, amplifier amplitude, deep rolling force, as well as the resulting surface and subsurface properties were identified.