目的 研究不同强力滚压工艺参数对超高强度钢表层残余应力分布的影响。方法 针对45CrNiMoVA超高强度钢的表面强化问题提出了强力滚压工艺。采用硬质合金滚压刀具，对试样施加超过2500 N的滚压力，进行强力滚压强化单因素试验。基于SEM和EBSD测试，分析强力滚压对超高强度钢表层微观组织的影响，进而对不同滚压参数下超高强度钢表层残余应力分布与表面残余应力变化进行分析。最后通过ABAQUS有限元仿真建立了超高强度钢强力滚压强化表层残余应力场预测模型，对滚压强化表层残余应力仿真值与试验值进行了对比。结果 强力滚压使得超高强度钢表层的平均晶粒尺寸从0.813 μm降低为0.474 μm，且马氏体晶粒沿滚压方向发生了变形滑移。超高强度钢经强力滚压后，表层残余压应力由–276 MPa提升至最高–942 MPa，残余压应力深度由0.2 mm增加至最大0.9 mm。超高强度钢强力滚压试验和仿真残余应力沿径向的分布规律一致，滚压表面残余压应力仿真值与试验值的误差小于27%。结论 测试分析表明，强力滚压可有效细化超高强度钢45CrNiMoVA表层晶粒并且改善残余应力分布，残余压应力值随着滚压深度和滚压次数的增加而增大，随进给量和工件转速的增大而减小。强力滚压仿真较为准确地预测出滚压强化表层残余应力分布情况，为超高强度钢45CrNiMoVA等一类难加工材料构件的表面强化问题提供了工艺指导。

This work aims to study the effects of different powerful rolling process parameters on surface residual stress distribution of ultra-high strength steel. In order to strengthen the surface of ultra-high strength steel, a powerful rolling strengthening process is proposed. Carbide rolling tools are used to apply rolling pressure greater than 2500 N to the sample. A single factor test of powerful rolling strengthening is carried out. Based on SEM and EBSD tests, the effects of powerful rolling strengthening on surface microstructure of ultra-high strength steel is analyzed. Furthermore, the residual stress distribution on the surface and surface layer of the ultra-high strength steel under different rolling parameters are analyzed. Finally, through ABAQUS finite element simulation, a prediction model for the residual stress field of ultra-high strength steel with powerful rolling strengthening is established. The simulated and experimental values of residual stresses are compared. As a result, powerful rolling strengthening refines the surface martensite grains of the ultra-high strength steel, reducing the average grain size from 0.813 μm to 0.474 μm, and the martensite grains deformation slip along the rolling direction. Powerful rolling strengthening can increase the residual compressive stress value of the ultra-high strength steel surface from –276 MPa to a maximum of –942 MPa, and the depth of the residual compressive stress from 0.2 mm to a maximum of 0.9 mm. The distribution of the residual stress in the radial direction of powerful rolling strengthening test and the simulation are consistent. The error between the simulation value and the experimental value of the rolling surface compressive stress is less than 27%. Test analysis shows that powerful rolling strengthening can effectively refine the surface grain of the ultra-high strength steel 45CrNiMoVA and improve the residual stress distribution. The residual compressive stress value increases with the increase of the rolling depth and the number of rolling times, and decreases with the increase of the feed rate and the workpiece speed. The powerful rolling simulation accurately predict the distribution of residual stress in the surface layer after rolling. It provides technical guidance for solving the surface strengthening problems of a class of difficult-to-cut materials such as ultra-high strength steel 45CrNiMoVA.