Abstract
Peening intensity and coverage are vital measurement outputs to quantify the quality of a peening process in the surface enhancement operation of metal parts. In practice, these parameters can only be measured offline upon process completion, which is not suitable for online tracking and operation. Instead, shot stream velocity can be used as a real-time monitoring parameter to bridge operational inputs to the outputs. As such, a robust and accurate shot stream velocity model is needed for real-time tracking. In this study, we propose a blended practical model for shot stream velocity to address the issues. The model is constructed using a regression algorithm based on the blended candidate functions, which are developed from the experimental data and nature of the particle-air flow inside the system. The obtained model is validated against the experimental data for ASR 70 media type for different operating conditions of the inlet airflow pressure and media flowrate. Calculated velocities are in good agreement with the measurements. In addition, the developed model is applied to predict the shot stream velocity for ASR 230 media type, as well as to evaluate the peening intensity and coverage for different media types under different operating conditions. The predicted results are comparable to the measurement data under the same operating conditions. The maximum relative error of the predicted shot stream velocity and measurement velocity is about 5%, while the maximum error in peening intensity is about ±0.0065 mmA. Furthermore, a single-input and single-output model-based control is developed based on the proposed shot stream velocity model. The developed control system is robust, accurate, and reliable. It implies that the developed model can be used to provide the necessary information, as well as to develop the optimal process control system to improve and accelerate the peening processes for cost and time reduction of actual production.
Highlights
Among surface enhancement techniques, shot peening is a highly efficient and relative low-cost method, which is widely used in aerospace [1] and automotive industries [2] to improve the fatigue life of metallic components [3]
To ensure that the model is valid and consistent, the model has to satisfy some constraints of particle-air flow nature; e.g, for a certain inlet air pressure, the stream shot velocity must be zero as the media flowrate increases to a certain maximum value, while the shot stream velocity achieves a maximum value as the media flowrate reduces to a certain minimum value
Concluding remarks and recommendations A blended practical model of shot stream velocity upon impact is developed based on both the experimental data and candidate functions to accurately describe the response of shot stream velocity to any change of inlet air pressure and media flowrate
Summary
Shot peening is a highly efficient and relative low-cost method, which is widely used in aerospace [1] and automotive industries [2] to improve the fatigue life of metallic components [3]. This study only focuses on the development of shot stream velocity model to link up the inlet air pressure and media flowrate to peening intensity. 3. Shot stream velocity model development As mentioned in previous section that the inlet air pressure and media flowrate are two control variables, which are manipulated to attain the target setting intensity and/or coverage. The shot stream velocity model is developed to link the inlet operational variables of inlet air pressure and media flowrate to the intermediate variable of shot stream velocity for process monitoring and control development, as well as other applications. In this study, this f2(∆p) candidate function is selected and added to the function library for blended model development later
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