Mathematical Modeling and Analysis of Surface Roughness Formation During Vibration-Centrifugal Hardening Based on Multi-Factor Experimentation

• Дата: 2026
• Автор: Климаш, І. В.
• Формат: Стаття
• Мова: Англійська; Українська
• Опубліковано: Інститут енергетичних машин і систем ім. А. М. Підгорного Національної академії наук України 2026
• Онлайн доступ: https://journals.uran.ua/jme/article/view/359599
• Назва журналу: Journal of Mechanical Engineering

Improvement of the operational reliability of critical machine parts is largely determined by the surface layer state formed during finishing operations. In this regard, research into surface plastic deformation processes, which combine structural strengthening with the achievement of minimum surface roughness, is of high relevance. The process of surface roughness formation in 30KhGSA steel during vibration-centrifugal hardening using fixed profiled rollers is studied in this paper. In contrast to processing in a loose abrasive medium, this approach ensures a deterministic character of the process and technological inheritance of the tool geometry on parts with stress concentrators. The aim of the paper is to establish quantitative regularities of the influence of technological factors: processing time (t), vibration amplitude (A), and working gap (Z) on the arithmetic mean deviation of the profile (Ra). To solve this problem, a full factorial experiment of the 23 type with logarithmic transformation of input variables, which allowed for the linearization of the power model and ensured high approximation accuracy, was applied. Statistical analysis using Cochran's, Student's, and Fisher's criteria confirmed the model's adequacy and revealed that the working gap (Z) is the dominant factor. A negative effect of excessive processing duration (over 8 min) was identified, leading to an increase in Ra due to micro-fatigue failure and the overshoot (surface peeling) phenomenon. Using the Box‑Wilson steepest ascent method, optimal modes were determined, ensuring a reduction in roughness from 6.45 μm to a predicted level of 1.68 μm. The resulting model (R=0.998) possesses high predictive capability and can serve as a mathematical foundation for algorithmizing finishing hardening operations and developing systems for technological production planning. The obtained results provide a basis for justifying the rational operating regimes of vibrational-centrifugal hardening with profiled tools, ensuring the formation of a stable microrelief and the induction of compressive residual stresses. This enhances the operational durability and fatigue strength of parts containing stress concentrators.