Effect of Ultrasonic Surface Rolling on Surface Integrity of High-carbon Q-P-T Steel

ZHANG Guangfeng; ZHANG Shentai; QIN Shengwei; SONG Zixin

doi:10.3969/j.issn.1674-6457.2026.07.017

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (7) : 184-193. DOI: 10.3969/j.issn.1674-6457.2026.07.017

Iron and Steel Forming

Effect of Ultrasonic Surface Rolling on Surface Integrity of High-carbon Q-P-T Steel

ZHANG Guangfeng¹, ZHANG Shentai², QIN Shengwei^2,*, SONG Zixin²

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Abstract

The work aims to investigate the effect of ultrasonic surface rolling process (USRP) parameters on the surface integrity of a high-carbon low-alloy Q-P-T steel with Fe-0.66C-1.48Mn-1.53Si-0.06Nb (wt.%). Ultrasonic surface rolling tests were conducted on the high-carbon low-alloy Q-P-T steel under different static pressures, rotation speeds, and amplitudes to examine the variations in the residual stress field. Meanwhile, the USRP process of the Q-P-T steel was simulated with the ABAQUS finite element software, and the changes in the residual stress field under different process parameters were analyzed. The experimental results showed good agreement with the simulation data, validating the reliability of the finite element model. When only a single parameter was varied and all other parameters are kept constant, as the static pressure, spindle speed, and amplitude increased, the maximum residual compressive stress increased to -975.82 MPa, -733.6 MPa, and -743.21 MPa, respectively, and the depth of the residual stress layer also increased. Compared with the state before ultrasonic rolling, the surface roughness decreased by 86.85% to 0.124 μm under a static pressure of 150 N (all roughness values in this work referred to Sa). However, excessive static pressure (750 N) caused the roughness to rebound to 0.411 μm. After USRP, the microhardness increased by approximately 50%, with a hardened layer depth of 450 μm, accompanied by significant grain refinement and plastic flow. After USRP, the maximum residual compressive stress of the samples increases with higher spindle speed, static pressure, and ultrasonic amplitude. Meanwhile, the plastic deformation in the surface layer of the samples significantly increases with greater static pressure. However, the improvement in surface roughness diminishes under higher static pressure.

Key words

ultrasonic surface rolling processing / high-carbon Q-P-T steel / finite element simulation / residual compressive stress / roughness / microhardness

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ZHANG Guangfeng, ZHANG Shentai, QIN Shengwei, SONG Zixin. Effect of Ultrasonic Surface Rolling on Surface Integrity of High-carbon Q-P-T Steel[J]. Journal of Netshape Forming Engineering. 2026, 18(7): 184-193 https://doi.org/10.3969/j.issn.1674-6457.2026.07.017

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Funding

National Natural Science Foundation of China (52001281); Education Department of Henan Province (25A430025, 23A460031, 25A460028); Henan Province Key R&D and Promotion Special Project (Science and Technology Tackling Project) (232102241022)