Influence of Tool Material on the Stress–Strain State of Components during Reversible Burnishing

The paper presents the results of numerical simulations of the reversible burnishing process applied to a C45 steel workpiece using rollers made of different materials, including SKD-11 tool steel, 42CrMo4 and 40Cr alloy steels, as well as quenched C45 steel. The objective of the study was to analyze the influence of the mechanical properties of the tool material on the key process parameters, including the stress–strain state of the workpiece, equivalent plastic strain, and accumulated plastic deformation energy. The simulations were performed using the Abaqus software package, taking into account the elastoplastic material behavior. The results show that the hardness and strength of the roller material have a significant effect on the process efficiency. SKD-11 steel, with a hardness of 58–62 HRC, provided the highest values of stress–strain state (with stress levels increasing by 20–29% compared to quenched C45 steel), while the equivalent plastic strain increased by a factor of 3.25 and the accumulated plastic deformation energy increased by 4.8 times. These findings confirm the decisive role of tool material in controlling the strengthening process and can be used to optimize surface plastic deformation technologies.
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