Author(s)

R. Schaal, B. Kaiser, B. Pyttel & C. Berger

Abstract

The influence of fillet rolling on fatigue strength - experiment and calculation R. ~chaal', B. ~aiser', B. pytte12 & C. ~ e r ~ e r ' I SIEMENS AG, Miihlheim an der Ruhr, Germany 2 Institute of Materials Technology, Darmstadt University of Technology, Germany Abstract Fillet rolling is a method that significantly improves the fatigue strength of members. Residual compressive stresses induced in the surface layer during the fillet rolling process are able to retard or prevent crack propagation. Large gains in fatigue strength up to 200% can be acheved. A procedure was developed to enable the fatigue strength calculation of fillet-rolled members. Two main topics had to be considered: The application of the FEM to simulate the rolling process and to calculate the residual stresses and the application of fracture mechanics to assess the effect of the compressive residual stresses on crack propagation. The influence of different process parameters can be investigated. After the simulation of fille

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