Journal of Materials Processing Technology 214 (2014) 2395–2401

Contents lists available at ScienceDirect

Journal of Materials Processing Technology

journal homepage: www.elsevier.com/locate/jmatprotec

Development of ultrasonic thread root rolling technology for

prolonging the fatigue performance of high strength thread
Cheng Minglong, Zhang Deyuan, Chen Huawei ∗ , Qin Wei
School of Mechanical Engineering and Automation, Beihang University, Beijing 100191, China

a r t i c l e i n f o a b s t r a c t

Article history: Fatigue failure commonly occurs at mechanical products, especially the threaded joints with high stress
Received 8 March 2014 concentration. Even though various high strength alloys are adopted, accidence due to fatigue failure
Received in revised form 9 May 2014 of thread still happens. As a novel method to improve the thread fatigue life, ultrasonic thread root
Accepted 11 May 2014
rolling (UTRR) process is developed in this paper. The configuration of the UTRR apparatus together with
Available online 15 May 2014
the principle of the UTRR is first introduced and described. Rolling experiments are then conducted on
AerMer100 thread specimens by use of the UTRR process and conventional thread root rolling (CTRR)
Keywords:
process respectively. Mechanical characteristics and fatigue properties for these treated specimens and
Ultrasonic thread root rolling
Thread root rolling process
untreated specimens are tested. Compared with CTRR, surface finish of thread root is farther improved
Fatigue performance from Ra 0.106 to Ra 0.051, and higher residual stress is achieved for UTRR. The depth of microstructure-
High strength steel refined zone induced in UTRR is about 20 ␮m, while that of CTRR is approximately 12 ␮m. These further
enhanced mechanical properties greatly contribute to the improvement of fatigue performance, and it is
well proved by fatigue results that an increase of about 7 times for fatigue life of AerMet100 specimens is
achieved after UTRR, while only 3 times is achieved for CTRR. Striations from fracture surface explicitly
confirm this result.
© 2014 Elsevier B.V. All rights reserved.

1. Introduction
Threaded joints, including threaded connections and fasten-
ers, are widely used to assemble mechanical structure in industry,
whose reliability greatly determines working performance of the
assembled mechanical structures (Saglam and Kus, 2011). How-
ever, fatigue failure commonly occurs in threaded joints (Symonds
and Pitt, 2006) due to high stress concentration. Although various
high strength alloys are adopted in threaded joints (Zhao et al.,
1995), fatigue failure is hardly avoided because high strength alloys
are more prone to stress concentration (Wan, 1994). Statistical data
has demonstrated that, in area of aerospace, more than 62% fail-
ures come from fatigue cracking, while 32% of the fatigue cracks
initiate from the thread joints (Findlay and Harrison, 2002). Thus
improving fatigue properties of high strength threaded joints is still
a worldwide research focus.
The cold rolling process is commonly used to improve the
fatigue performance of threaded joints by effectively enhancing the
mechanical properties of thread root (Knight et al., 2003). And mul-
tiple investigations have been conducted on this process to make it
∗ Corresponding author. Tel.: +86 01082339717; fax: +86 01082316603.
E-mail addresses: chenhw75@buaa.edu.cn, chen hua wei@yahoo.com (H. Chen).
more practical. Dowie (1959) investigated the effect of cold rolling
process parameters on the fatigue performance, and demonstrated
that the material properties, the applied force, the number of
passes, and the roller shape had great impact on the fatigue perfor-
mance of a cold rolled thread. Kim et al. (2007) studied the effect of
penetration rate of rolling tool on the fatigue strength and residual
stress of groove-rolled products and found that higher compressive
stress and higher fatigue strength were obtained when higher pen-
etration rate was used. Knight et al. (2005) experimentally showed
that the fatigue life of drilling threaded connection was improved
26 times via cold rolling process with proper parameters. However,
almost all of these studies on the cold rolling process were limited to
materials with middle yield strength and low hardness such as AISI
4145H and S45C. Song et al. (1995) studied the fatigue property of
300M thread treated by CTRR, while the result showed that fatigue
strength was improved only 79% due to limited plastic deforma-
tion in the high strength thread. Thus, it is of great importance to
develop an effective method to improve the fatigue performance of
high strength thread, especially those made of ultra-high strength
steel.
Over past decades, various ultrasonic surface enhancement
techniques (USET), such as ultrasonic surface rolling processing
(USRP), ultrasonic deep cold rolling (UDCR), ultrasonic-aided deep
rolling (UADR), and ultrasonic cold forging technology (UCFT),

http://dx.doi.org/10.1016/j.jmatprotec.2014.05.019
0924-0136/© 2014 Elsevier B.V. All rights reserved.
2396 M. Cheng et al. / Journal of Materials Processing Technology 214 (2014) 2395–2401

Fig. 1. Configuration of UTRR apparatus.

have been developed to overcome fatigue failure by integrat-
ing ultrasonic technology into conventional surface enhancement
process. Bozdana et al. (2005) studied the effect of UDCR on sur-
face characteristics of Ti–6Al–4V components and found that high
residual stress and great work hardening was achieved using
the UDCR process. Wang et al. (2008) investigated evolution of
nanocrystallization layer of 40Cr treated by USRP and found that
nano-structured layer, with grain size of 3–7 nm, was formed after
the USRP process. Xie et al. (2013) reported that nanocrystallization
also occurred on 30CrMnSiNi2A Steel treated by the UADR process.
All these studies confirmed that mechanical properties of specimen
surface could be enhanced by USET, which was useful for improving
fatigue resistance of products. Fatigue property of treated products
by USET was also experimentally investigated. Zhu et al. (2009)
studied the effect of UADR on rotating bending fatigue performance
of Ti–6Al–4V and found that the fatigue strength increased from
375 MPa to 612 MPa via the UADR. Suh et al. (2007) reported that
an increase of about 25% in fatigue limit was obtained by UCFT. Cao
et al. (2010) studied the relation between vibration strike numbers
and fatigue life of products treated by UCFT and found that fatigue
life was improved with the increase of vibration numbers. How-
ever, almost all of these studies about USET mainly focus attention
on smooth specimens, where the stress-concentration is not obvi-
ous. It is still necessary to comprehensively study the effect of USET
on fatigue performance of high stress-concentration screw thread
because of urgent demands on safety.
In this paper, a novel thread fatigue property enhancement
method, i.e. UTRR is proposed. The mechanical structure and the
working mechanism of UTRR are briefly described. Various exper-
iments are conducted to roll the AerMet100 thread specimens
by UTRR and CTRR, and fatigue tests are carried out for these
treated and untreated specimens. The microstructure and mechani-
cal properties of these AerMet100 specimens are compared to make
clear the effect of UTRR on fatigue performance.
amplifying and transmitting the ultrasonic vibration, the thread
roller (tungsten carbide), the force control unit and an adjustable
preloading spring. The UTRR apparatus can be mounted onto the
saddle of any conventional lathe or CNC machine center. The static
force is applied by radial feed of the lathe saddle and is maintained
stable by accurate control of force control unit. In the duration of
cold rolling process, the thread roller vibrates on root surface along
with move of the tool. The UTRR rolling process and the CTRR rolling
process are achieved by switching on or off the ultrasonic generator.
The power output of the ultrasonic generator is about 600 W.
The UTRR process exhibits unique characteristic of high energy
input compared with conventional thread root rolling (CTRR) pro-
cess. The rolling force in UTRR is shown in Fig. 2 where T is period
of vibration, Fsta static force, Fmax maximum force, Fa amplitude of
dynamic force. As shown in Fig. 2, dynamic force occurs when ultra-
sonic vibration is applied onto the thread roller. The total force F in
UTRR is the sum of static force and dynamic force, which is shown
in Eq. (1). From a micro perspective, the total force can be divided
into two regions, the vibration effective region and the unload-
ing region. In the vibration effective region, the maximum force is
the sum of static force and amplitude of dynamic force, which can
generate larger plastic deformation than the static force applied

2. Apparatus and description of the UTRR process

A novel UTRR apparatus is developed, whose configuration is

shown in Fig. 1. The UTRR apparatus consists of the ultrasonic gen-
erator (frequency of 20 kHz), the piezo-transducer unit, the booster Fig. 2. Characteristic of dynamic force in UTRR.
 M. Cheng et al. / Journal of Materials Processing Technology 214 (2014) 2395–2401
Fig. 3. Dimension of the fatigue specimen.
alone. In the unloading region, the total force is decreased to a
value smaller than the static force. As thousands of strikes occur
per second at a small region, the maximum force determines the
total plastic deformation in the process, while the effect of low force
is neglected. In addition, as reported by Suh et al. (2007), strength
of the dynamic energy is 2.5–5 times larger than the static energy.
Thus, alternative force with larger amplitude and high frequency
is applied on the root surface during the UTRR process. Ratchet-
ing then occurs for the root material as thousands of cyclic loading
per second is applied on a small region of root surface. Ratchet-
ing here is a cyclic accumulation of plastic deformation, which
occurs under the stress-controlled cyclic loading with non-zero
mean stress (Hassan and Kyriakides, 1992). Eq. (2) from previous
paper of Cai et al. (2002) shows that plastic strain increases due to
ratcheting,
F = Fsta + Fa sin(2ft)
εr = εsr (1 − ˛N ˇ )
εsr
where is saturated ratcheting strain related to maximum stress,
˛ and ˇ are material factors depended on stress status, and N is
number of cycles for alternative stress.
Thus, severer plastic deformation and deeper enhanced layer
can be generated for the UTRR as compared with the CTRR, which
is valuable for improving fatigue resistance of high strength thread.
3. Specimens and experimental procedures
The high strength steel AerMet100, which is widely used in
aerospace field, is chosen as the material of specimens. The chem-
ical composition of AerMet100 is 13.82% Co, 11.73% Ni, 3.13% Cr,
1.25% Mo, 0.23% C, 0.096% Mn in wt.%. The AerMet100 specimens
are heat-treated with the mechanical properties: yield strength
1718 MPa, tensile strength 1930 MPa, and elongation 14%. A cylin-
drical pipe thread specimen is prepared for fatigue testing as shown
in Fig. 3 All the test specimens are machined to its demanded thread
accuracy after heat treated.
A tungsten carbide roller with the same edge profile as thread
root is adopted in this study, and the diameter of the roller is 25 mm.
The rolling process is realized on a conventional lathe, and kerosene
is chosen as lubricant. The specimens are divided into three groups,
i.e. untreated, CTRR-treated and UTRR-treated, each group has four
specimens. The process parameters for UTRR and CTRR process are
shown in Table 1. The static force is determined in such a way that
all thread specimens should meet the accuracy demand after the
rolling process.
The morphologies and roughness of the thread root surface
are observed using a white light interferometer 3D optical profiler
(AEP Technology). The residual stress along depth of thread root
is measured by X-ray tester (PROTO iXRD). Microstructure of all
2397
Table 1
Process parameters for CTRR and UTRR.
Process parameters CTRR-treated UTRR-treated
Static load (N) 1500 1500
Speed (rpm) 9 9
Rolling passes 1 1
Amplitude of vibration (␮m) – 3
Frequency of vibration (kHz) – 21
specimens is observed with a metalloscope (ZEISS Axiovert 200
MAT). The cross section along the thread root is obtained by wire
electrode cutting technology. After being mechanically polished,
the cross sections are then etched at room temperature in a solution
of 4% nital. To investigate the effect of UTRR process on the fatigue
behavior of AerMet100 thread, tension–tension fatigue testes on
the three groups of specimens are conducted on a tensile fatigue
(1)
test machine (INSTRON 8803). All specimens are tested at ambient
(2) temperature. The frequency of fatigue testing is 5 Hz. The maxi-
mum tensile stress is 600 MPa, and the stress ratio is 0.1. In order to
verify the fatigue test results, the fracture surface of each specimen
is examined using a scanning electron microscopy (JSM-6010LA).
4. Results and discussion
4.1. Morphology and roughness of root surface
Fig. 4 shows the observation of root surface features for three
groups of specimens, where the left hand side shows the original
features and the right hand side is the features after filtering. The
figures show that surface finish of thread root is further improved
after UTRR compared with that for specimens treated by CTRR.
For the untreated specimens, visible tool marks are observed
along the cutting direction, which turn into cracks source after
alternating load is applied. After the UTRR process, tool marks
along the cutting direction are almost eliminated, while visible
tool marks still appear on root surface of CTRR treated specimen.
The surface roughness of specimen is also obtained by the white
light interferometer 3D optical profiler, and Ra values are shown
in Table 2. It is clear that the surface finish is farther improved
from Ra 0.106 to Ra 0.051 by UTRR compared with CTRR. This
can be explained by that large plastic deformation is generated,
which is the result of high dynamic force induced by the ultrasonic
Table 2
Roughness values of root surface for untreated and treated specimens.
Process Root surface roughness Ra (␮m)
Untreated 0.194
CTRR-treated 0.106
UTRR-treated 0.051
2398 M. Cheng et al. / Journal of Materials Processing Technology 214 (2014) 2395–2401

Fig. 4. Surface morphology of thread root for different specimens: (a and b) untreated; (c and d) CTRR-treated; (e and f) UTRR-treated.

vibration. The improvement of surface finish and tooth marks
reduction greatly inhibit the fatigue crack nucleation, which is
indeed helpful for achieving high fatigue resistance.
4.2. Microstructure of cross section
The cross-sectional microstructures for the three groups of
specimens (untreated, CTRR-treated and UTRR-treated) are shown
in Fig. 5. Compared with untreated specimens, a microstructure
refined zone can be observed in both of the UTRR-treated spec-
imens and CTRR-treated ones. The surface region for these two
treated specimens then can be divided into two zones from the
surface to the core: the grain-refined zone and the coarse grains
zone. In the grain-refined zone, the grains are extruded and elon-
gated. The elongation orientation of grains is almost parallel to
the root direction, clearly revealing the processing effect. The
shapes of grains in grain-refined zone are difficult to identify
under optical microscope, while the grains in the basic material
are needle-like. In addition, the microstructure on the surface is
further refined by UTRR than by CTRR, as a white layer appears
on the UTRR-treated specimen. Previous study of Cao et al. (2010)
shows that surface refinement of microstructure can help to retard
crack initiation, even though the cracks initiate from the sur-
face of specimens. From these figures, it also can be found that
deeper microstructure-refined zone is formed in UTRR-treated
specimens than in CTRR-treated specimens. Due to lack of accu-
rate method to identify the microstructure-refined zone, the depth
of the microstructure-refined zone is approximately determined
on basis of visual analysis of microstructure (Wu et al., 2013). The
average depth of microstructure-refined zone induced by UTRR is
 M. Cheng et al. / Journal of Materials Processing Technology 214 (2014) 2395–2401
Fig. 5. Microstructures of cross section for different specimens: (a) untreated, (b) CTRR-treated and (c) UTRR-treated.
about 20 ␮m, while that of CTRR is approximately 12 ␮m. Although
the measured depth is a little bit influenced by subjective view,
the result is qualitatively acceptable. In the UTRR process, about
20,000 strikes per second occur on a small region of thread root
and thousands of alternative stress per second is applied on the
same area, which results in ratcheting. As is known from previ-
ous study of Hassan and Kyriakides (1992), plastic deformation
greatly increases when ratcheting occurs, which leads to deep
layer of refined microstructure. In addition, the large maximum
of dynamic force is also helpful for generating deeper refined
microstructure. Therefore, the introduced vibration on the roller
is helpful for refining microstructure and increasing the depth
of microstructure-refined zone which is beneficial for inhibiting
cracks nucleation.
4.3. Distribution of residual stress
Residual stress at the thread root cannot be tested by direct use
of the X-ray method, because the thread root is in a small region
which is beyond the measuring limit of X-ray tester. Thus, in this
study, material of thread tooth is first removed. Fig. 6(a) shows the
process for residual stress detection. After rolling process, tooth of
thread is grinded on a grinding machine. The electrical–chemical
layer removal technique is consequently adopted to eliminate the
mechanical effect of grinding process and also used to obtain every
new layer. The depth distribution of axial residual stress for differ-
ent specimens is shown in Fig. 6(b). It is observed that compressive
residual stress is induced for the two groups of specimens treated
by UTRR and CTRR, while tensile axial residual stress with small
value exists in the untreated specimens. The same spoon-like stress
Fig. 6. Detection and distribution of residual stress at thread root: (a) process for residual stress detection, (b) distribution of axial residual stress for different specimens.
2399
profiles are exhibited for the two treated specimens, which well
corresponds with the simulation result from study of Kim et al.
(2007). The residual stress both increases first and then decreases
with the increase of depth, and reaches the maximum value at
the same depth, about 125 ␮m beneath the surface. It can also
be found that obvious difference exists between the two stress
curves. For the UTRR process, the residual stress attains a value
of −470 MPa at the root surface and gets the maximum value of
−647 MPa beneath root surface. While for the CTRR process, the
residual stress is −403 MPa at surface and reaches the maximum
value of −588 MPa beneath root surface. What is more, the total
depth of compressive residual stress induced by UTRR is slightly
deeper than that induced by CTRR. In brief, both the value and the
region of compressive residual stress generated in the UTRR process
are larger than that in the CTRR process. This can be explained by
that the residual stress is related to the degree of plastic deforma-
tion at surface, which is larger in UTRR than in CTRR because of the
dynamic force property. The distribution of compressive of stress
plays a very important role in inhibiting nucleation and expansion
of fatigue cracks.
4.4. Fatigue behavior and fracture analysis
The fatigue life of three groups of specimens and their average
fatigue life are shown in Table 3. It is easy to find that the average
fatigue life for CTRR-treated specimens is about 3 times of untreated
specimens, while the average fatigue life for UTRR-treated speci-
mens is about 7 times of untreated specimens. In other words, the
improvement of fatigue life by UTRR process is 2 times longer than
by CTRR process. The fatigue test results indicate that the UTRR
2400 M. Cheng et al. / Journal of Materials Processing Technology 214 (2014) 2395–2401

Fig. 7. SEM micrograph of fracture surface for specimen untreated (2.5 × 104 cycles, a–c), CTRR-treated (7.8 × 104 cycles, d–f), UTRR-treated (21 × 104 cycles, g–i).

process is extremely effective to improve the fatigue performance UTRR process. The enlarged micrographs of cracking sources show
of thread which is made from ultra-high strength materials. that smoother fracture surface is observed for UTRR-treated spec-
Fig. 7 shows SEM micrographs of the fracture surface for three imen than for the other groups of specimens, which indicates that
specimens. Cracks of all specimens are initiated on the surface and fatigue cracks expand more slowly in the former specimen than in
propagate toward the interior region. For the untreated specimen, the latter two groups of specimens. And this is well confirmed by
multiple cracks sites are found on the fracture surface, while for fatigue striation patterns shown in Fig. 7(c), (f) and (i). These fig-
the UTRR-treated and CTRR-treated specimens, single crack site ures show the fatigue striation patterns near the crack initiation
is observed. Just like untreated specimen, cracks for CTRR-treated site of the three groups of specimens. It is evident from these fig-
specimen also initiate from the micro-defect in the tool marks, ures that fracture surface of CTRR-treated specimen exhibits denser
while there is no evident defect for the UTRR-treated specimen. and finer striation, whereas the fracture surface of untreated spec-
This is identical to the result from surface morphology test, which imen shows coarser striations. However, no evident striation can
means that the cracking sources are significantly reduced after the be found from UTRR-treated specimen meaning that the striation
is extremely dense. This can be explained by that higher compres-
sive residual stress and higher work hardening induced by refined
Table 3
microstructure can effectively inhibit cracking expansion and slow
Fatigue life of three groups of specimens. the expansion speed. The striation of the fracture surface also shows
that the improved surface finish together with the introduced com-
Process Fatigue life (N)
pressive residual stress and refined microstructure do effectively
No. 1 No. 2 No. 3 No. 4 Average restrain the crack initiation and expansion, which directly prolongs
Untreated 25,341 27,946 31,507 33,735 29,632 the fatigue life of specimen. The experimental results effectively
CTRR-treated 78,345 88,165 103,792 127,157 99,364 confirm that the ultrasonic vibration in the UTRR process is bene-
UTRR-treated 198,393 215,462 227,830 261,758 225,860 ficial for improving fatigue life of high strength thread.
 M. Cheng et al. / Journal of Materials Processing Technology 214 (2014) 2395–2401
5. Conclusion
An ultrasonic assisted thread rolling technology, i.e. UTRR,
was developed. The mechanism of the UTRR process was briefly
introduced. Compared rolling experiments on AerMet100 thread
specimens were conducted using UTRR and CTRR processes.
Mechanical characteristics and fatigue properties of the specimens
were tested and analyzed. The results showed that fatigue lives
of threads which were made from ultra-high strength steel Aer-
Met100 could be effectively improved by the UTRR process. A
fatigue life improvement of about 7 times was achieved by the
UTRR process, while only 3 times improvement was obtained by the
CTRR process. Surface finish was farther improved from Ra 0.106
for CTRR to Ra 0.051 for UTRR. Apart from better surface finish,
the novel UTRR process could acquire higher compressive resid-
ual stress and deeper refined microstructure layer as compared
with the CCPR process. The depth of microstructure-refined zone
induced in UTRR was about 20 ␮m, while that of CTRR was approx-
imately 12 ␮m. For UTRR process, the maximum value of residual
stress was −647 MPa while only −588 MPa for that of CTRR pro-
cess. These mechanical properties, which were further enhanced by
ultrasonic vibration, greatly contributed to further improvement
of fatigue life for high-strength thread components, which was a
challenge for other surface strength processes.
Acknowledgement
This project is supported by National Natural Science Founda-
tion of China (Grant no. 51305018).
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