Relationship between microhardness and carbide in deep rolling of Al6061-T6 material with new type rolling insert

Deep rolling is a surface modification technique based on the principle of rolling metal surfaces by plastic deformation with the help of a rolling insert tip. In this technique, different rolling tools, such as ball and roller, are used. In this study, a rolling tool compatible with existing tools was designed and used in deep rolling of Al6061-T6 alloy. The effect of the rolling tip used on the surface was examined and evaluated. For this purpose, three different rolling forces, feed rates, and spindle speeds were selected, and experiments based on the L27 orthogonal design were carried out for the rolling process. The surface hardness of the rolled surfaces was measured, and the effects of surface morphology and parameters on carbide mass on the surface were examined. As a result, it was observed that carbide was observed in deep rolling with the manufactured rolling insert tip, and thus, the microhardness increased. It was observed that carbide increases in parallel with the increase in spindle speed and rolling force and decreases with the increase in feed rate. It was also observed that the effects of the parameters on carbide mass are rolling force, spindle speed, and feed rate, respectively.