Disclosed are a method and system to form a contoured structure using deep rolling. The method includes using deep rolling to introduce plastic deformation to one or more portions of a work piece to form a convex contour in the work piece. The work piece, and subsequently formed contoured structure, can be metal or composite. The disclosed deep rolling systems and methods form, for example contoured aircraft panels, while also providing fatigue strength improvement and low level of work hardening during the forming process rather than as a post-production surface treatment.

A method of forming a component from a powder metal includes forming the component to a desired shape from the powder metal, heating the component to a burnishing temperature of 900 to 1300 degrees Fahrenheit, and burnishing a surface of the component while the component is at the burnishing temperature to densify the surface.

Various kinds of finishing and hardening treatments of holes by methods of plastic surface deformation can find application in many branches of engineering industry. In particular for burnishing holes on a milling or drilling machine tool. A device for diamond-burnishing of holes increases the functional possibilities, improves the quality of the treated hole surface and the endurance of the burnishing tool, provides the opportunity for a precise regulation in order to get the necessary hole caliber, and uses the load of all the weights for obtaining the necessary pressing force. The device structure comprises a housing with a tapered stem, central and terminal arms with crossheads and shafts, bars with weights, a foot with a cylindrical body, and an arbor with a diamond-burnishing tool.

A repaired article includes a body extending between a first side and a second side. The body has a repair section with an associated thickness between the first side and the second side. The repair section includes regions of plastic deformation distributed through the thickness. A gas turbine engine including the body is also disclosed.

A repaired article includes a body extending between a first side and a second side. The body has a repair section with an associated thickness between the first side and the second side. The repair section includes regions of plastic deformation distributed through the thickness. A gas turbine engine including the body is also disclosed.

Processing tool for processing a surface of a workpiece. The processing tool includes a tool body which defines a tool axis. At least one first roll element, which is borne by the tool body, is rotatable around a first roll element axis and has a first outer surface with a rough surface structure in at least one first working section configured for rolling contact with the workpiece surface. Further, at least one second roll element, which is borne by the tool body, is rotatable about a second roll element axis and has a second outer surface that, in at least one second working section configured for a rolling contact with the workpiece surface, has a distance (r2) to the tool axis, which is less than a distance (r1) of the at least one first working section to the tool axis.

A method for chipless machining of a surface region of a rolling-element bearing ring includes rotating the rolling-element bearing ring relative to a first tool having a first tool tip and a second tool having a second tool tip, positioning the first and second tool tips at start positions at first and second opposite axial ends of the surface region, and moving the first and second tools in opposite axial directions such that the first tool tip follows a first helical or spiral path on the surface region and the second tool tip follows a second helical or spiral path on the surface region, the first and second paths crossing at multiple points within an overlap region located between axial ends of the surface regions.

A method for chipless machining of a surface region of a rolling-element bearing ring includes rotating the rolling-element bearing ring relative to a first tool having a first tool tip and a second tool having a second tool tip, positioning the first and second tool tips at start positions at first and second opposite axial ends of the surface region, and moving the first and second tools in opposite axial directions such that the first tool tip follows a first helical or spiral path on the surface region and the second tool tip follows a second helical or spiral path on the surface region, the first and second paths crossing at multiple points within an overlap region located between axial ends of the surface regions.

A segmented mandrel for cold working having two forward segments and two rear segments positioned between the two forward segments, when fitted together have an approximately circular outline. The two forward segments and the two rear segments are movable separately and together.

A method of forming a component includes heating the component to a burnishing temperature above 500 degrees Fahrenheit, and burnishing a surface of the component while the component is at the burnishing temperature to densify the surface. The burnishing process at an elevated temperature may be integrated into other processes, such as the sintering or heat treating processes.