Influence of Shot Peening Parameters on Process Effectiveness

2012 ◽  
Author(s):  
Abdalla Elbella ◽  
Fawaz Fadul ◽  
Sri Harsha Uddanda ◽  
Nagender Reddy Kasarla
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Process Parameters ◽  
Shot Peening ◽  
Incidence Angle ◽  
Target Material ◽  
Stress Profile ◽  
Surface Strength ◽  
Residual Stress Profile ◽  
The Impact

The shot peening process is known for the surface treatment of metallic components. The process is used to enhance surface strength and extend component fatigue life by introducing a compressive residual stress pattern in the surface layers of the component. Numerical simulation of the shot peening process is a tool that has been recently used to help control the process. The simulation helps in investigating the effects of the process parameters with an aim of attaining the optimum residual stress profile and maximum process gain. In this paper, elasto-plastic finite element simulation is used to perform this investigative analysis. The process parameters that are varied in this analysis are: the shot diameter, shot velocity, incidence angle and target material. The analysis is to be carried for three different materials, namely, steel, aluminum and titanium. An Explicit commercial finite element code (ABAQUS) is used to simulate the impact phenomenon. The results of the analysis are sets of varying plots of residual stress through the depth of the targets.

A Sensitivity Analysis of Shot Peening Parameters

2006 ◽  
Author(s):  
Abdalla Elbella ◽  
Vishal Rami ◽  
Jyothi Hogirala
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Process Parameters ◽  
Shot Peening ◽  
Target Material ◽  
Element Model ◽  
Stress Profile ◽  
Explicit Finite Element ◽  
Residual Stress Profile ◽  
Subsurface Layers

Shot peening process is largely used for surface treatment of metallic components with the aim of increasing surface toughness and extending fatigue life. The fatigue strength of the component can be improved by inducing compressive residual stress in the surface and subsurface layers by the shot peening process. Numerical simulation of the shot peening process is an important tool that is used to aid in understanding the effects of the process parameters on intended goal of attaining the optimum residual stress profile and maximum process gain. In this paper an elasto-plastic finite element model is used for the shot peening process. The process parameters that are varied in this analysis are: the shot diameter, shot speed, number of shots at a given time (coverage) and target material. The analysis is carried out for two different materials, namely, steel and aluminum. An Explicit finite element code (ABAQUS) is used to perform this task. These parameters have different effects on the resulting residual profile and the results of the study showed that by adjusting these parameters, the most effective residual stress profile could be obtained.

Study of the Effect of Thickness on the Residual Stress Profile of a Cold Spray Coating by Finite Element Analysis

2021 ◽  
Author(s):  
Felipe Torres ◽  
Ruben Fernandez
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Cold Spray ◽  
Spray Coating ◽  
Stress Profile ◽  
Element Analysis ◽  
Residual Stress Profile ◽  
Cold Spray Coating ◽  
The Impact

Abstract The understanding of residual stress is of critical importance in the cold spray and thermal spray processes. It has a direct effect on the integrity of the coating related to the adhesion strength, fatigue life, and can lead to undesired effects such as the delamination of the coating. In cold spray, several investigations have evaluated the impact of the residual stress on the coatings, and it is generally accepted that cold spray coatings follow a similar profile to those obtained in the shot peening process. Although the measurement of residual stresses gives fundamental insight into the process, the estimation of such stresses considering the deposition of each layer by numerical methods has not been extensively studied. This work proposes a method for analyzing the evolution of residual stress on a cold spray coating, both on the coating and the substrate, as a function of the deposited layers, using Finite Element Analysis (FEA). The evolution of the residual stress profile with the coating thickness was obtained along the transverse direction. The results were compared to experimental and numerical data from previous studies. The influence of the deposition of each layer on the residual stress profile has been discussed.

Finite Element Simulation of the Residual Stress States after Shot Peening

2006 ◽  
Vol 524-525 ◽  
pp. 349-354 ◽  
Author(s):  
Manuel Klemenz ◽  
Volker Schulze ◽  
Otmar Vöhringer ◽  
Detlef Löhe
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Finite Element Simulation ◽  
Shot Peening ◽  
Three Dimensional ◽  
Material Model ◽  
Stress Profile ◽  
Viscoplastic Material ◽  
Residual Stress Profile ◽  
Element Simulation

In a three-dimensional Finite-Element-Simulation of shot peening, a combined isotropickinematic viscoplastic material description was introduced in order to describe the cyclic softening effects during peening. After verifying the model in the simulation of push-pull tests at different strain amplitudes it could be used for the shot peening simulation. The simulated residual stress profile is compared with experimental results determined by X-ray diffraction and with simulated results of a simpler isotropic viscoplastic material model.

Study of Effect of Repetition Rate on Laser Shock Peening Using Finite Element Modeling

2020 ◽  
Author(s):  
Sai Kosaraju ◽  
Xin Zhao
Keyword(s):  
Shock Wave ◽  
Residual Stress ◽  
Finite Element ◽  
Shock Waves ◽  
Repetition Rate ◽  
High Repetition Rate ◽  
Stress Profile ◽  
Surface Residual Stress ◽  
Residual Stress Profile ◽  
High Repetition

Abstract A two-dimensional finite element model is developed to simulate the interaction between metal samples and laser-induced shock waves. Multiple laser impacts are applied at each location to increase plastically affected depth and compressive stress. The in-depth and surface residual stress profiles are analyzed at various repetition rates and spot sizes. It is found that the residual stress is not sensitive to repetition rate until it reaches a very high level. At extremely high repetition rate (100 MHz), the delay between two shock waves is even shorter than their duration, and there will be shock wave superposition. It is revealed that the interaction of metal with shock wave is significantly different, leading to a different residual stress profile. Stronger residual stress with deeper distribution will be obtained comparing with lower repetition rate cases. The effect of repetition rate at different spot sizes is also studied. It is found that with larger laser spot, the peak compressive residual stress decreases but the distribution is deeper at extremely high repetition rates.

scholarly journals Parametric Study of Fixtured Vibropeening

Metals ◽  
2019 ◽  
Vol 9 (8) ◽  
pp. 910 ◽  
Author(s):  
Chan ◽  
Ahluwalia ◽  
Gopinath
Keyword(s):  
Residual Stress ◽  
Process Parameters ◽  
Continuous Treatment ◽  
Optimal Time ◽  
Process Time ◽  
Time Range ◽  
Work Piece ◽  
Stress Profile ◽  
Process Step ◽  
Residual Stress Profile

Vibropeening is a surface treatment process, which combines the peening effect of introducing residual stress with the polishing effect of reducing surface roughness in one single process step. Vibropeening equipment induces vibrations into the media to impart residual compressive stresses in sub-surface layers, as well as polishing on the surface of the work piece. In addition to process parameters, such as vibration frequency, amplitude, and media mass, which are well known in literature, this paper will focus on the study of two additional parameters: immersion depth and process time. It was found that the lower-middle section of the vibratory trough produced the highest Almen deflection. Different continuous treatment times were also studied to explore the maximum introducible residual compressive stress state, and it was concluded that an optimal time range is required to achieve the best residual stress profile. The study demonstrates that different process parameters can influence the effectiveness of the vibropeening process, and that these can be potentially optimized for higher treatment capability.

A New Finite Element Approach Without Chip Formation to Predict Residual Stress Profile Patterns in Metal Cutting

2009 ◽  
Author(s):  
S. Anurag ◽  
Y. B. Guo ◽  
Z. Q. Liu
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Hard Turning ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Stress Profile ◽  
Residual Stress Profile ◽  
Stress Prediction ◽  
Element Approach ◽  
Stress Profiles

Residual stress prediction in hard turning has been recognized as one of the most important and challenging tasks. A hybrid finite element predictive model has been developed with the concept of plowed depth to predict residual stress profiles in hard turning. With the thermo-mechanical work material properties, residual stress has been predicted by simulating the dynamic turning process followed by a quasi-static stress relaxation process. The residual stress profiles were predicted for a series of plowed depths potentially encountered in machining. The predicted residual stress profiles agree with the experimental one in general. A transition of residual stress profile has been recovered at the critical plowed depth. In addition, the effects of cutting speed, friction coefficient and inelastic heat coefficient on residual stress profiles have also been studied and explained.

Numerical Analysis of the Effect of Machining on the Depth of Yield, Maximum Firing Pressure and Residual Stress Profile in an Autofrettaged Gun Tube

2003 ◽  
Vol 125 (3) ◽  
pp. 342-346 ◽  
Author(s):  
Amer Hameed ◽  
R. D. Brown ◽  
J. G. Hetherington
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Optimization Technique ◽  
Circumferential Stress ◽  
Element Model ◽  
Stress Profile ◽  
Residual Stress Field ◽  
Element Analysis ◽  
Residual Stress Profile ◽  
Experimental Findings

A multi-linear kinematic, two dimensional finite element model incorporating Bauschinger effect, developed using ANSYS commercial software is used to determine the effect of machining both at the bore and at the outside diameter, on the depth of yield, maximum firing pressure and final residual stress field present in an autofrettaged gun tube. The model, which is in good agreement with experimental findings, clearly shows that the reduction in maximum compressive circumferential stress is more sensitive to internal machining than to external machining; the depth of yield remains stable and there is no movement of the elastic-plastic interface, relative to its location before material removal. If the internal machining removes material in which reverse yield has occurred, the maximum firing pressure is not affected. The finite element analysis supported by experimental evidence thus leads to an optimization technique for gun tube design.

Approach by Simulation of Residual Stress Generated by Shot-Peening and Their Stability during Fatigue Cycling

2011 ◽  
Vol 681 ◽  
pp. 303-308
Author(s):  
H. Michaud ◽  
Jean Michel Sprauel ◽  
Chedly Braham
Keyword(s):  
Residual Stress ◽  
Process Parameters ◽  
Shot Peening ◽  
Low Cycle Fatigue ◽  
Fatigue Behaviour ◽  
X Ray Diffraction ◽  
Alloy Steels ◽  
Spring Leaf ◽  
Usual Process ◽  
The Impact

ASCOMETAL produces alloy steels used for spring (leaf or coil), where the weak fatigue points are on the surface which is reinforced by shot-peening. So, the fatigue optimization with the steel grade needs a perfect knowledge of the material answer after shot-peening. For that reason, an analytical model has been developed where low cycle fatigue behaviour and all the usual process parameters are integrated (especially the impact position, and the covering-rate). Moreover, through a Monte-Carlos approach, the model permits to analyse the effect of scattering elements like impact speeds, ball sizes, or material fatigue behaviour. With this model several key process parameters have been analysed and validated with residual stress profiles evaluated by X-ray diffraction. So, for spring leaf, the effect of an applied load during shot-peening or shakedown during bending fatigue is described.

Assessment of Residual Stress Profiles for Fitness for Service Assessment of Pipe Girth Welds

2014 ◽  
Author(s):  
Pingsha Dong ◽  
Shaopin Song ◽  
Jinmiao Zhang
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Solution Procedure ◽  
Stress Profile ◽  
Full Field ◽  
Residual Stress Profile ◽  
Estimation Scheme ◽  
Detailed Assessment ◽  
Stress Profiles ◽  
Girth Welds

This paper aims to provide a detailed assessment of some of the existing residual stress profiles prescribed in widely used fitness-for-service assessment codes and standards, such as BS 7910 Appendix Q, by taking advantage of some comprehensive residual studies that become available recently. After presenting a case study on which residual stress measurements are available for validating finite element based residual stress solution procedure, residual stress profiles stipulated in BS 7910 for girth welds are evaluated in the context of a series of parametric finite element results and a shell theory based full-field residual stress estimation scheme. As a result, a number of areas for improvement in residual stress profile development are identified, including some specific considerations on how to attain some of these improvements.

scholarly journals The Effects of Shot Distance and Impact Sequence on the Residual Stress Field in Shot Peening Finite Element Model

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 462
Author(s):  
Zhou Wang ◽  
Ming Shi ◽  
Jin Gan ◽  
Xiaoli Wang ◽  
Ying Yang ◽  
...  
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Stress Distribution ◽  
Shot Peening ◽  
Dynamic Models ◽  
Fe Simulation ◽  
Residual Stress Distribution ◽  
Fe Model ◽  
Residual Stress Field ◽  
The Impact

In order to investigate the effect of shot distance and impact sequence on the residual stress distribution of 42CrMo steel in shot peening (SP) finite element (FE) simulation, 3D dynamic models with order dimple pattern and stochastic dimple pattern were established via ABAQUS/Explicit 6.14, and the simulation results were compared with experiments. The results show that shot overlap has a significant effect on the residual stress distribution of peened parts. Meanwhile, there is a threshold (related to SP parameter) for shot distance in the vertical and horizontal directions. When the shot distance is greater than the threshold in this direction, the residual stress distribution after SP tends to be stable. The impact sequence has almost no effect on the impact of a small number of shots, but this effect will appear when the number of shots increases. It is necessary to avoid shot overlap and continuous impact of adjacent dimples when the FE model is established; on this basis, the distance between shots and the number of layers of the shots can be reduced as much as possible without affecting the residual stress distribution. In addition, the comparison of simulation and experimental results shows that the residual stress evaluation area consistent with the experimental measurement is essential to obtain accurate residual stress distribution in the FE simulation process.

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