3D Model of Shot Dynamics for Ultrasonic Shot Peening

2013 ◽  
Vol 768-769 ◽  
pp. 503-509 ◽  
Author(s):  
Jawad Badreddine ◽  
Emmanuelle Rouhaud ◽  
Matthieu Micoulaut ◽  
Sebastien Remy ◽  
Vincent Desfontaine ◽  
...  
Keyword(s):  
Residual Stress ◽  
Process Parameters ◽  
Spatial Data ◽  
Shot Peening ◽  
3D Model ◽  
Prediction Models ◽  
Dissipated Energy ◽  
Displacement Fields ◽  
Ultrasonic Shot Peening ◽  
Stress Prediction

This paper presents a 3D model that simulates an ultrasonic shot peening (USP) operation, using realistic process parameters and peening setups (part and chamber geometries). By simulating the shot dynamics (shot trajectories and impacts), statistical and spatial data are obtained for the peened component, i.e. surface coverage and coverage rate, impact speeds and angles, dissipated energy... This data can then be used for i) optimizing the design of peening chambers and process parameters and ii) predicting the residual stress and displacement fields induced by USP in the peened component. In fact, data from the 3D model can be used as initial data in existing residual stress prediction models. A chaining methodology was developed for this purpose and allows linking the choice of process parameters and USP setup to the induced residual stress displacement fields.

Modelling of the Ultrasonic Shot Peening Process

2005 ◽  
Vol 490-491 ◽  
pp. 67-72 ◽  
Author(s):  
C. Pilé ◽  
Manuel François ◽  
Delphine Retraint ◽  
Emmanuelle Rouhaud ◽  
Jian Lu
Keyword(s):  
Process Parameters ◽  
Vibration Frequency ◽  
Shot Peening ◽  
Boltzmann Distribution ◽  
Perfect Gas ◽  
Average Speed ◽  
Speed Distribution ◽  
Almen Intensity ◽  
Ultrasonic Shot Peening ◽  
The Impact

The aim of this work is to reach a better understanding of the ultrasonic shot-peening process and, in particular, the evolution of the shot speed distribution. A simple 1D modelling of the interaction between the shots and the sonotrode is carried out. The impact is considered as inelastic with an energy absorption that depends on the speed of the shot. It is found that after about 10 interactions (» 1s) the speed distribution in the chamber follows a Maxwell-Boltzmann distribution, which is the distribution found in a perfect gas at equilibrium. The influence of various process parameters such as the sonotrode amplitude, the vibration frequency on the average speed and on the Almen intensity is studied.

Numerical Simulation of Residual Stress Field Induced by Ultrasonic Shot Peening

2008 ◽  
Vol 373-374 ◽  
pp. 832-835 ◽  
Author(s):  
Gang Ma ◽  
Xiang Ling ◽  
Yuan Song Zeng
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Stainless Steel ◽  
Shot Peening ◽  
Compressive Residual Stress ◽  
Diffraction Method ◽  
Residual Tensile Stress ◽  
Finite Element Software ◽  
Ultrasonic Shot Peening ◽  
Stress Layer

A 3D finite element model is established to simulate the ultrasonic shot peening process by using a finite element software ABAQUS. The residual stress distribution of the AISI 304 stainless steel induced by ultrasonic shot peening (USP) is predicted by finite element analysis. Ultrasonic shot peening (USP) process can cause a compressive residual stress layer on the surface of the material. During the simulation, many factors, e.g., ultrasonic shot peening duration, initial residual stress, hourglass, etc., are taken into consideration for the purpose of optimizing the process. The simulation results show that ultrasonic shot peening can produce a compressive residual stress layer on the surface of the material even if there is initial residual tensile stress (250MPa) and the longer peening duration. The residual stress of simulation were compared with the experiment data which were obtained under the same ultrasonic shot peening parameters and have a good agreement with the measurement values by X-ray diffraction method. In conclusion, ultrasonic shot peening is an effective method for protecting weldments against stress corrosion cracking by introducing the compressive residual stress layer into the surface of stainless steel.

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.

Development of Ultrasonic Shot Peening Technique for Reactor Components to Improve Structural Integrity Against Stress Corrosion Cracking

2009 ◽  
Author(s):  
Shohei Kawano ◽  
Ayaka Kawagishi ◽  
Nobuichi Suezono ◽  
Kenichi Ueno ◽  
Ken Okuda ◽  
...  
Keyword(s):  
Residual Stress ◽  
Stainless Steel ◽  
Stress Corrosion ◽  
Stress Corrosion Cracking ◽  
Shot Peening ◽  
Structural Integrity ◽  
Weld Line ◽  
Corrosion Cracking ◽  
Experimental Result ◽  
Ultrasonic Shot Peening

The ultrasonic shot peening (USP) technique has been developed for boiling water reactor (BWR) components as a countermeasure against stress corrosion cracking. The effects on residual stress of USP for type 316L stainless steel and alloy 600 were evaluated. Compressive residual stress layer of 0.5 mm from the surface were formed on the specimens after USP using stainless steel ball with a diameter of 3 mm. Cross-sectional hardness measurement revealed that the increase of hardness due to USP is not significant compared with shot peening (SP). The FEM calculation showed the plastic strain induced by the impacts of 3 φ shot with 5 m/s is lower than those of 0.6 φ shot with 50 m/s. It suggests USP process suppresses the degree of work hardening in comparison with SP process. Dissimilar weld joint specimens which simulate the material and dimension of the shroud weld line H7 were examined to confirm the applicability of USP. The experimental result reveals that USP technique is applicable to reactor internal components as stress modification process.

The Ability of Current Models for Fatigue Life Prediction of Shot Peened Components

2009 ◽  
Vol 417-418 ◽  
pp. 901-904 ◽  
Author(s):  
Ricardo A. Cláudio ◽  
José M. Silva ◽  
Carlos M. Branco ◽  
Jim Byrne
Keyword(s):  
Residual Stress ◽  
Fatigue Life ◽  
Fracture Mechanics ◽  
Shot Peening ◽  
Life Prediction ◽  
Compressive Residual Stress ◽  
Prediction Models ◽  
Critical Distance ◽  
Fatigue Life Prediction ◽  
Distance Methods

It is well known that shot peening has a marked benefit on fatigue life for the majority of applications. This effect is attributed mainly due to the compressive residual stress state at the component’s surface due to shot peening. The present paper evaluates the ability of several fatigue life prediction models, commonly used for general analyses, to predict the behaviour of components with compressive residual stress due to shot peening. Advanced elastic-plastic finite element analyses were carried out in order to obtain stress, strain, strain energy and fracture mechanics parameters for cracks within a compressive residual stress field. With these results several total fatigue life prediction models (including critical distance methods) and fracture mechanics based models were applied in order to predict fatigue life. Fatigue life predictions were compared with several experimental fatigue tests carried out on specimens, representative of a critical region of a compressor disc in a gas turbine aero engine. The results obtained showed that total fatigue life methods, even if combined with critical distance methods, give conservative results when shot peening is considered. Fatigue life was successfully predicted using the method proposed by Cameron and Smith, by adding initiation life to crack propagation life. This last method was also successfully applied for the prediction of non-propagating cracks that were observed during the experimental tests.

scholarly journals Simulation of shot peening: From process parameters to residual stress fields in a structure

2016 ◽  
Vol 344 (4-5) ◽  
pp. 355-374 ◽  
Author(s):  
Donato Gallitelli ◽  
Vincent Boyer ◽  
Maxime Gelineau ◽  
Yann Colaitis ◽  
Emmanuelle Rouhaud ◽  
...  
Keyword(s):  
Residual Stress ◽  
Process Parameters ◽  
Shot Peening ◽  
Stress Fields

scholarly journals Influence of process parameters on the residual stress state and properties in disc springs made by incremental sheet forming (ISF)

2021 ◽  
Author(s):  
Muhammad Junaid Afzal ◽  
Ramin Hajavifard ◽  
Johannes Buhl ◽  
Frank Walther ◽  
Markus Bambach
Keyword(s):  
Residual Stress ◽  
Stress State ◽  
Residual Stresses ◽  
Process Parameters ◽  
Shot Peening ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Installation Space ◽  
Residual Stress State ◽  
Compressive Residual Stresses

AbstractDisc springs are machine elements that are used when high forces need to be supplied and in limited installation space. They need to fulfil high demands on the stability of the spring characteristics, reliability and lifetime. In corrosive environments, metastable austenitic stainless steels (MASS) disc springs are often used. Tensile stresses that occur during service limit the lifetime of disc springs. Usually, their durability is enhanced by generating favorable compressive residual stresses using shot peening operations. Such operations lead to extra efforts and additional production costs. In this study, the adaptive and targeted generation of residual stresses via incremental sheet forming (ISF) is investigated as alternative to shot peening focusing on EN 1.4310 and EN 1.4401 stainless steel. Previous work has shown that ISF is capable of controlling the radial and tangential stresses in the springs. However, no analysis of the influence of the residual stress state in the rolled sheet strips and the ISF process parameters was performed. The goal of the current work is to analyze the evolution of residual stress during rolling and subsequent incremental forming of disc springs. In order to examine the role of dissipation and temperature increases in the rolling process, sheet blanks rolled at room and elevated temperature are analyzed. The characteristics of the compressive residual stresses induced by ISF are studied for different process parameters. X‑ray diffraction is used to investigate the buildup of these stresses. Using ISF, the generation of compressive residual stresses can be integrated into the forming process of disc springs, and further post-treatment may be skipped. The results show that the residual stress state in the rolled material is crucial, which requires tight control of the rolling temperature. Another result is that ISF is able to yield high compressive residual stresses and improved spring characteristics when small tool diameters and step-down values are used.

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