Finite element analysis of stress-strain state of the deformation zone of a UFG TI Grade 4 workpiece subjected to abrasive-free ultrasonic finishing

An effective approach to increasing the fatigue resistance of metal products is to create compressive residual stresses on the surface of the product using surface plastic deformation (SPD) processing. One of the effective SPD methods is the process of abrasive-free ultrasonic finishing (AFUF). Another well-known approach to improving mechanical properties including fatigue resistance is to create an ultrafinegrained (UFG) structural state in the product. This research focuses on the finite-element study of the stress-strain state of a UFG workpiece subjected to SPD by the AFUF method. Commercially pure Grade 4 titanium in the UFG state obtained by the ECAP-Conform method was chosen as a workpiece material. In the course of the study, the stress-strain state of the deformation zone was analyzed after a single indentation with subsequent unloading under the elastic-plastic scenario. The effect of the indenter oscillation amplitude and its geometry on radial residual stresses including their depth of occurrence, average normal stress and strain intensity was analyzed. It was found that as the indenter radius increases, the strain intensity (e) value decreases. The e parameter distribution has a gradient nature with a decrease in values from the surface to the center of the workpiece. An analysis of simulation results shows that radial residual stresses in the deformation zone are predominantly compressive, and, accordingly, they will increase the fatigue resistance of the finished product. It was established that as the indenter oscillation amplitude increases, the values of compressive radial residual stresses also increase. Their maximum values reach 540 MPa at an amplitude of 75 μm with the depth of these stresses up to 0.3 mm. An increase in the indenter radius, i.e. in fact the contact area, leads to an increase in the magnitude of compressive radial residual stresses with an almost linear behavior.