目的 实现高效率、低表面粗糙度和大残余压应力制造。方法 利用ANSYS软件建立12Cr2Ni4A齿轮钢外圆超声滚压有限元模型，分析超声滚压加工后，残余应力场的分布规律。搭建12Cr2Ni4A齿轮钢试验平台，研究工艺参数对工件表层残余应力的影响规律。同时对有限元模型进行验证。运用非线性曲线拟合方法，构建超声滚压工件表面残余应力及其表面粗糙度预测模型，基于赫兹接触理论和压痕几何关系，建立外圆超声滚压加工效率理论模型。结果 经过超声滚压加工后，12Cr2Ni4A齿轮钢表层残余压应力显著提升，且沿滚压深度方向，呈现先增大后减小趋势。最大残余压应力随着初始静压力的增加，峰值点逐渐从表层向次表层移动，最大残余压应力值为?654 MPa，此时硬化层深度约为0.8 mm。经优化得到最优参数为:F=315 N，vf=0.32 mm/min，n=269 r/min。结论 12Cr2Ni4A齿轮钢表层残余压应力随静压力的增大，呈线性增加趋势，随主轴转速和进给量的增大略微减小。参数优化后，加工效率得到进一步提升，工件能够获得良好的表面状态。

The work aims to realize the high efficiency, low surface roughness and large residual compressive stress manufacturing. The finite element model for cylindrical ultrasonic rolling of 12Cr2Ni4A gear steel was established with ANSYS software. After the ultrasonic rolling was analyzed, the test platform was built according to the distribution laws of residual stress field to study the effect of processing parameters on residual stress of workpiece. Meanwhile, the finite model was confirmed. The prediction models of surface residual stress and surface roughness were established by the multiple nonlinear regression method. Based on the Hertz contact theory and indentation geometry, the theoretical model of cylindrical ultrasonic rolling was established. After ultrasonic rolling, the surface residual compressive stresses firstly increased and then decreased along the direction of rolling depth after. As the static forces increased, the peak of compressive residual moved from surface to substrate, the maximum residual compressive stress was ?654 MPa, and the thickness of hardness layer was about 0.8 mm. The optimal parameters were obtained as F=315 N, vf=0.32 mm/min and n=269 r/min. The residual compressive stress increases linearly with the increase of static force, and decreases slightly with the increase of spindle speed and feed rate. The machining efficiency is further improved after optimization, and a good workpiece surface can be obtained.