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Residual stresses of those which remain in the material even after removing the entire external load. Residual stresses may be compressive or tensile depending on the type of the external loads. Compressive residual stresses improve the mechanical properties particularly the fatigue life of material. Compressive residual stresses can be induced by different techniques. Due to its easiness and low cost, deep rolling is one of the widely used techniques in industry to create compressive residual tresses. Deep rolling process is numerically simulated in this work and the effects of some important rolling parameters such as ball diameter, feed rate, penetration depth, and number of passes on the distribution of residual stress are investigated. Chaboche cyclic plasticity model is used in the simulations. The constants of the Chaboche model are calculated from the strain control cyclic tests on Al 7075. The results are validated using the experimental and numerical results reported in the literature. The results indicate that the depth and magnitude of the compressive residual stress increase with the ball diameter increase, depth of penetration and number of passes. Also, the value of residual stress and its uniformity decrease by increasing the feed rate. In addition, Chaboche cyclic plasticity model can simulate material behavior in a low cycle loading such as deep rolling and using finite element method instead of experimental methods for measuring residual stresses reduces cost and time of solution and reveals more depth of residual stress distribution.

Keywords: Deep rolling, Numerical simulation, Residual Stress, Chaboche plasticity model

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