Correlation between process load and deep rolling induced residual stress profiles

Deep rolling is often used as a finishing step after cutting because of its beneficial influence on surface and subsurface properties, which lead to an increase in performance and lifecycle behavior. This manufacturing process is suitable to reduce roughness and to induce compressive residual stresses. As thermal effects only play a minor role in the deep rolling process, it is possible to link the resulting residual stresses to the analytically determined internal process loads. The boundaries of these relationships are investigated on hardened AISI 4140 using different mechanical loads and overlap factors.