Bending Fatigue Behaviour and Fatigue Endurance Limit Prediction of 20Cr2Ni4A Gear Steel after the Ultrasonic Surface Rolling Process

To study the effect of the surface properties on the bending fatigue performance of heavy-duty gear steel, the authors of this paper used the ultrasonic surface rolling process (USRP) to strengthen 20Cr2Ni4A carburized gear steel. USRP is a novel technique in which the ultrasonic technology is incorporated into the concept of conventional deep rolling. In this study, we illustrated how the surface properties and cross-section mechanical property influence the three-point bending fatigue life of the samples before and after USRP treatment. At the same time, the predicted failure probability-stress-number of cycles (P-S-N) curve was drawn, and the fatigue fracture was analysed. The results show that the fatigue limit increased from 651.36 MPa to 918.88 MPa after USRP treatment. The fatigue source is mainly from the sample interior or surface scratches, and the fatigue performance is positively correlated with the results of the material surface roughness, surface residual stress and surface hardness. At the same time, combined with the change in the phase structure, dislocation structure, residual stress and hardness of the cross section of the material, it is found that the USRP process turns the steel into a gradient material with five layers. Finally, the coupling mechanism between the ultrasonic surface strengthening deformation layer and the carburized layer of 20Cr2Ni4A carburized gear steel is presented, and the grain structure distribution diagram of the section of the 20Cr2Ni4A model after surface strengthening treatment was simulated. The mechanism that influenced the fatigue performance after USRP treatment is explained from the perspectives of the surface and cross section of the samples.