A numerical investigation into the influence of the slide burnishing process on the real surface roughness and residual stress profiles of AHSS

Abstract

Finite element models of the burnishing process for galvanized Advanced High-Strength Steels (AHSS) sheets were developed. To reduce the number of points that describe a real surface profile, optimization algorithms were implemented, considering three sequential stages: (1) surface profile filter, (2) mean line determination and, (3) eight roughness parameters validation. The finite element models developed accurately reproduce the experimental roughness profile, obtained with different burnishing forces. Also, the effect of the real surface roughness on the residual stress distribution was numerically investigated by considering the interaction between the coating layer present on the steel. The simulation showed that considering the real surface strongly influences the residual stress profile on the surface and to a certain depth.

Keywords

• Roughness parameters
• Dual phase
• TRIP
• Surface finishing process
• Residual stresses
• Finite element model