Effect of process parameters on stress and strain of hybrid deposition and micro-rolling

Purpose This paper aims to summarize the influence law of hybrid deposited and micro-rolling (HDMR) technology on the shaping strain and residual stress. And the rolling parameters combination was further optimized to guide the actual production. Design/methodology/approach This paper proposed a three-dimensional coupled thermo-mechanical model of the HDMR process. The validated model is used to investigate the influences of rolling parameters on stress and plastic strain (the distance between the energy source and roller [ D e–r ], the rolling compression [ c r ] and the friction coefficient [ f r ]). The orthogonal optimization of three factors and three levels was carried out. The influence of rolling parameters on the plastic strain and residual stress is analyzed. Findings The simulation results show that HDMR technology can effectively increase the shaping strain of the weld bead and reduce the residual tensile stress on the weld bead surface. Furthermore, the influence of rolling parameters on stress and strain is obtained by orthogonal analysis, and the corresponding optimal combination is proposed. Also, the rolling temperature significantly affects the residual stress, and the rolling reduction has a substantial effect on the plastic deformation. Research limitations/implications Owing to the choice of research methods, this paper failed to study microstructure evolution. Originality/value This paper provides a reference principle for the optimal selection of rolling parameters in HDMR.