Abstract
The effectiveness of shot peening is mainly determined by the peening coverage. The peening coverage is required to be 100% for current technical standards of shot peening. With the increase of material strength, higher peening coverage is required in shot peening process. However, the influence of high peening coverage on Almen intensity and residual compressive stress is unclear, the difficulty mainly lies in the lack of quantitative description of peening coverage in finite element analysis. To analyze the influence of high peening coverage on Almen intensity and residual compressive stress, firstly an approximate quantitative description of peening coverage based on dent size, the distance of shots and shot numbers is proposed in this study. Based on this quantitative description of peening coverage, the arc height and residual stress of the Almen test are simulated with the finite element method. The simulation results of arc height and saturation curve agree well with that of the Almen test, by which the effectiveness of the quantitative description and FE simulation are proved. The further study indicates that in shot peening processes, the excessive peening coverage doesn’t improve Almen intensity and residual compressive stress.
Highlights
Shot peening is a mechanical surface treatment that induces a surface layer of residual compressive stress (RCS)
In the shot peening process, the surface of metal parts such as gears, springs, or turbine blades is sprayed by numerous small round metal balls and RCS is generated on the surface
The relation of impact locations and sequence of shots has been investigated in these studies, which establishes the foundation for a quantitative description of peening coverage in this paper
Summary
Shot peening is a mechanical surface treatment that induces a surface layer of residual compressive stress (RCS). Atig et al [12] proposed a probabilistic methodology to evaluate the variability of the induced residual stress and Almen intensity of the shot peening parameters. Mylonas and Labeas [26] proposed a methodology that minimizes a total number of shots, and makes it possible practically to simulate the multiple shot impacts, which have statistics characteristics They showed that predetermined shot patterns (locations and sequence of the multiple shots) on a reference area of 1 mm could predict RCS distribution, surface roughness, and cold work by comparing the model-predictions with measurements. The relation of impact locations and sequence of shots has been investigated in these studies, which establishes the foundation for a quantitative description of peening coverage in this paper. To analyze the influence of peening coverage on Almen intensity and residual compressive stress, further study is carried out. Through the discussion of the FE simulation and Almen test results, some new conclusions are obtained
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