Abrasive waterjet (AWJ) peening can be used for metal surface strengthening by introducing near-surface plastic strain and compressive residual stress. The present studies seldom focus on residual stress by AWJ peening of targets with different geometrical features. In fact, those targets usually exist on some machine parts including gear roots, shaft shoulders, and stress concentration areas. According to Hertz theory of contact and Miao's theoretical model for predicting residual stress of flat surface, this paper developed a theoretical model for investigating residual stress of targets with different geometrical features including concave arc surface, concave sphere surface, convex arc surface, and sphere surface. AWJ peening of targets with different geometrical features and different radii of Gaussian curved surface was simulated by abaqus. Theoretical results were consistent with numerical simulation results and published experimental results (H. Y. Miao, S. Larose, et al., 2010, “An analytical approach to relate shot peening parameters to Almen intensity,” Surf. Coat. Technol., 205, pp. 2055–2066; Cao et al., 1995, “Correlation of Almen arc height with residual stresses in shot peening process”, Mater. Sci. Technol. 11, pp. 967–973.), which will be helpful for predicting residual stress of gear roots, shaft shoulders, and stress concentration areas after AWJ peening. The research results showed that under the same peening parameters, σmax, σtop, dmax, and dbottom in concave surface (including concave arc surface and concave sphere surface) were the maximum; σmax, σtop, dmax, and dbottom in convex surface (including convex arc surface and sphere surface) were the minimum; for concave surface, σtop, σmax, dbottom, and dmax decreased, respectively, with target radius; for convex surface, σtop, σmax, dbottom, and dmax increased, respectively, with target radius.

A novel peripheral milling process with an end milling cutter for manufacturing aluminum fibers is proposed. Most of the cutting is done by the peripheral teeth of the cutter and the chips removed by the teeth form aluminum fibers, while the cutter end has little effect on aluminum fibers. The machining principle and the formation mechanism of aluminum fiber cross-section are presented. The feasibility of this new fabrication process is experimentally investigated under different machining conditions. In addition, influences of cutting parameters on the equivalent diameter, the length, and surface morphology of aluminum fibers are analyzed. Experimental results indicate that aluminum fibers can be successfully manufactured by peripheral milling and the productivity can be improved by increasing the rotational speed n. Smaller radial depth of cut a _e , larger rotational speed n, and smaller feed speedv _f are in favor of obtaining slim aluminum fibers. The length of aluminum fibers is theoretically determined by the axial depth of cut a _p and also actually affected by other cutting parameters. Of all the cutting parameters considered in these experiments, the optimum parameters of a _e , n, and v _f are 0.3 mm, 118 r/min, and 60 mm/min, respectively.

As an important finish machining process, the grinding process plays an important role in the equipment manufacturing industry. This paper gives a quick overview of the development of surface integrity theory, illustrates the important influence of surface integrity on the fatigue life of component, introduces the development and research status of grinding process, and states the theory and application of grinding process with superior surface integrity after the case hardening or surface modification of key component.