Shot Peening Residual Stresses Research Articles

An analytical model for predicting residual stress in shot peening with strain energy method

In this study a model by novel analytical approach is developed and experimentally verified for shot peening residual stress distribution. The residual stress field induced by single shot impact is calculated by using Glinka–Molski energy-based method and kinematic hardening model. The formulation of the compressive residual stress (CRS) distribution is often based on plane strain or plane stress. It can be determined from the derived relation presented in this paper, the final residual stress in the full coverage conditions is the average of the two strain and stress plane expressions proposed by previous researchers. The distribution of residual stress is one of the key differences between the profiles produced by the results of the current model. There is a significant distinction between surface residual stress and maximum CRS, because the CRS profile near the surface is more curved compared to profiles obtained in earlier analytical models. The experimental data obtained by XRD analysis indicate the correctness and precision of the current model. Another goal of this study is to increase the fatigue life of GTD-450 stainless steel by shot peening at two different peening intensities. The fatigue life of samples were obtained by rotary bending test. Analytical results that confirmed by experimental findings shown bigger maximum compressive residual stresses occurred in higher shot peening intensities. This incident can improved fatigue life by deeper plastically deformed layer.

High-precision simulation and experimental verification of residual stress and surface topography of cylindrical surface shot peening

Shot peening is commonly employed for surface deformation strengthening of cylindrical surface part. Therefore, it is critical to understand the effects of shot peening on residual stress and surface topography. Compared to flat surface, cylindrical surface shot peening has two significant features: (i) the curvature of the cylindrical surface and the scattering of the shot stream cause distributed impact velocities; (ii) the rotation of the part results in a periodic variation of the impact velocity component. Therefore, it is a challenge to quickly and accurately predict the shot peening residual stress and surface topography of cylindrical surface. This paper developed a high-precision model which considers the more realistic shot peening process. Firstly, a kinematic analysis model was developed to simulate the relative movement of numerous shots and cylindrical surface. Then, the spatial distribution and time-varying impact information was calculated. Subsequently, the impact information was used for finite element modeling to predict residual stress and surface topography. The proposed kinematic analysis method was validated by comparison with the discrete element method. Meanwhile, 9310 high strength steel rollers shot peening test verified the effectiveness of the model in predicting the residual stress and surface topography. In addition, the effects of air pressure and attack angle on the residual stress and surface topography were investigated. This work could provide a functional package for efficient prediction of the surface integrity and guide industrial application in cylindrical surface shot peening.

The Impact of Induced Shot Peening Residual Stresses on Metallic Components of SAE 1020 Steel with Pre-Existing Compressive Stresses

The Impact of Induced Shot Peening Residual Stresses on Metallic Components of SAE 1020 Steel with Pre-Existing Compressive Stresses

Analytical prediction of shot peening residual stress distribution using inherent strain in aluminum–magnesium alloy plates under various peening conditions

Analytical prediction of shot peening residual stress distribution using inherent strain in aluminum–magnesium alloy plates under various peening conditions

Simulation and Experimental Investigation of Multi-Step Shot Peening for Surface Crack Repair in Aluminum Alloys

This study explores the impact of shot peening residual compressive stress on repairing surface cracks in the 7075-T651 aluminum alloy. Two models were developed for crack repair via shot peening and fatigue test finite element modeling. A multi-step numerical simulation introduced shot peening-induced residual stress into the fatigue test model, and subsequent simulations analyzed the crack repair mechanism. The research results indicate that increasing pressure and projectile size improve repair effectiveness, but higher pressure causes material damage, and larger projectiles decrease fatigue life. Crack repair effectiveness decreased with higher loading levels, more significantly at higher loads. Experimental and simulation results matched well, validating the simulation model for shot peen repair processes and offering optimization possibilities.

Prediction of the effect of shot peening residual stress on fretting fatigue behaviour

Fretting occurs at two contact bodies, which sustain oscillation loading. The fretting phenomenon decreases the fatigue lifetime dramatically. Shot peening is a commonly used surface treatment to enhance the resistance to damage because the residual stress is introduced to the surface of the material. Some studies showed that residual stress was helpful to improve fatigue lifetime. Under fretting fatigue condition, there are two main stages: crack initiation stage and the crack propagation stage. In this paper, the authors apply the Critical Plane (CP) method combined with the Theory of Critical Distance (TCD) to study the fretting fatigue crack initiation behaviour under the influence of shot peening residual stress, including the crack initiation position, orientation and the crack initiation lifetime. Meanwhile, the Linear Elastic Fracture Mechanics (LEFM) theory and the Extension Maximum Tangential Stress (EMTS) criterion are adopted to study crack propagation behaviour considering shot peening residual stress effect. The results show that the methods applied in this paper can make good predictions of fretting fatigue behaviour, including both initiation and propagation stages. Meanwhile, the influence of residual stress in these two stages are studied as well.

A Discrete-Finite Element Analysis Model Based on Almen Intensity Test for Evaluation of Real Shot Peening Residual Stress.

In this study, a combined discrete-finite element model based on the Almen intensity measurement test was proposed to evaluate the real shot peening residual stress. The discrete element analysis was utilized to simulate the random behavior of numerous shot balls, while the finite element analysis was employed to quantitatively predict the residual stress induced by shot peening. Moreover, the Almen intensity, an essential factor in the actual shot peening process, was taken into account. Initially, an Almen strip analysis model was established, and the multi-random impact analysis was performed to validate the good agreement between the analytical Almen curve and experimental Almen curve. Subsequently, the unit cell discrete-finite element analysis model was expanded for predicting the peening residual stress, incorporating the Almen intensity. The analysis results showed a significant correlation between the predicted peening residual stress and the XRD (X-ray diffraction) experimental residual stress. Therefore, it was confirmed that the proposed discrete-finite element random impact analysis model in this study could serve as an effective analytical technique capable of substituting for the actual shot peening process.

Effects of shot peening residual stresses on fatigue crack propagation behavior of 316L

To study the influence of shot peening residual compressive stress on the fatigue crack propagation behavior of 316L austenitic stainless steel, a three-dimensional finite element model of the compact tensile specimen based on abaqus software and an initial stress simulation model of a shot peening residual stress imported through the re-development of the SIGINI subroutine are established. The fatigue crack propagation behavior under the combined effect of the shot peening residual stress field and external cyclic loading is investigated using the extended finite element method. The results show that the crack propagation path and fatigue life obtained by the finite element method are in good agreement with the experimental results, and the error of the fatigue life is only about 4.05%. When the crack propagates into the shot peening region, the shot peening residual compressive stresses imported on the specimen surface and subsurface enhance the crack closure effect and suppress the crack propagation behavior. The impact of shot peening in the double side peened samples is higher than that in the single side peened samples. For 19 mm crack lengths, double side shot peened specimens presented a 1.2 times increase in fatigue life, compared to single side shot peened specimens (1.1 times).

Research Progress of the Effect of Shot Peening Residual Stress on Fatigue Performance and Deformation Control

Research Progress of the Effect of Shot Peening Residual Stress on Fatigue Performance and Deformation Control

A calculation model of TC4 shot peening residual stress based on elastic-plastic theory

Shot peening is widely used in automobile, aviation, and other industries because it can change the fatigue strength of metal structures by introducing residual compressive stress field on the surface and significantly improve the fatigue life of mechanical structures. In order to improve the surface properties of parts after shot peening, an analysis method for rapidly predicting residual stress of parts surface during shot peening is proposed. During the analysis, an elastoplastic impact model of shot was established, and stress–strain laws in three processes of elastic loading, plastic deformation and stress release were studied. The residual stress under different shot peening parameters was predicted by considering the plastic strengthening effect of TC4 (Ti-6Al-4V). A TC4 shot peening test was performed and residual stress was measured, and the results are consistent with the model predictions, which verified correctness of the model.

Analysis of shot peening residual stress distribution based on dislocation configuration

The distribution profile of residual stress on the surface layer of shot-peened materials is often in a hook shape. We analysed the distribution characteristics of residual stress by detecting dislocation configurations. The position of maximum compressive residual stress (MCRS) shifts inward with an increase in shot peening strength. It was found that long-term orderly dislocation pile-up groups frequently appeared in the MCRS region. The location of MCRS is not necessarily related to maximum dislocation density. At low strength, both the maximum dislocation density and the MCRS are on the surface region. At high strength, the surface region structures are composed of sub-grains and dislocation cells. The position of maximum dislocation density is between the surface region and the MCRS.

Optimal shot peening residual stress profile for fatigue

Shot peening (SP) is frequently used as a palliative measure against metal fatigue in many engineering components. The performance of this surface treatment depends on different factors including the material, shape and loading conditions of the component, as well as process parameters. Fatigue improvement due to SP depends to a great extent upon the in-depth compressive residual stress profile produced in the specimen.In this work, we study the optimum shape for a residual stress profile in terms of fatigue behaviour. For this task, we assume a residual stress profile that is qualitatively similar to that produced by SP in many metals. Based on this generic profile, we analyse the optimum shape for two simple, but noteworthy, fatigue cases: plain fatigue and notch fatigue. The analysis is conducted in the “fatigue damage tolerance design” framework, in which a certain initial defect is assumed to be present in the component under study.

Fretting fatigue and shot peening: a multiaxial fatigue criterion including residual stress relaxation

Fretting fatigue damage is a typical material damage arising in mechanical components. In such a damage condition, surface cracks can initiate at the surface contact zone, and under a fluctuating loading they can grow up to the complete failure of the component, resulting in a catastrophic failure.In order to prevent/mitigate fretting fatigue damage, shot peening is widely used in mechanical components. The improvement due to shot peening is related to different factors, but the main one is the compressive residual stress field produced by such a treatment in a region near the contact surface. Unfortunately, both the uncertainty in measurements and stability (relaxation) of residual stress field, make shot peening effects difficult to be included in models aimed to the estimation of fatigue life. Due to this lack in the literature, especially relatively to the fretting fatigue field, in the present paper a new fretting fatigue model, that is able to consider shot peening residual stress and its relaxation, is presented. A 3D elastic-plastic finite element model, which incorporates the shot peening residual stress and its relaxations, is employed. The results obtained, in terms of stress field, are used as input data of a multiaxial stress-based criterion to estimate both fatigue lifetime and crack initiation direction.

An analysis of fatigue failure mechanisms in an additively manufactured and shot peened IN 718 nickel superalloy

The family of additive manufacturing techniques has been attracting significant attention of manufacturers and researchers, due to its unrivalled flexibility to fabricate and repair geometrically complex objects. However, material shaping is not sufficient: wide adoption of additive manufacturing can only occur upon the achievement of satisfactory mechanical performance in terms of structural integrity. The present study exploits a wide range of micro-scale experimental techniques to shed light on fatigue failure mechanisms of Laser Metal Deposition IN718 Ni-base superalloy, and to study the effect of shot peening treatment. Thorough microstructural and fractographic analyses revealed the main deformation mechanism associated with twinning during crack propagation, while crack initiation was found to be promoted by both slip system deformation and twinning around microstructural defects, rather than at sample free-surfaces. It was found that precipitates played a major role in determining the deformation mode. It was discovered that in this case-study, shot-peening residual stresses may have a detrimental effect, in view of the presence of the largest defects within a region where tensile residual stress was present. The results presented here improve understanding of failure mechanisms and thus define future directions of development for manufacture optimisation.

Effect of shot peening residual stresses and surface roughness on fretting fatigue strength of Al 7075-T651

Fretting fatigue is a surface damage phenomenon appearing in mechanical contacts subjected to time variable contact forces. Typical features of fretting fatigue include: wear, oxidation, high stress concentration and non-proportional loading. The high stresses near the surface produce a rapid initiation of cracks. Among the different fretting fatigue palliatives, one of the most common is shot peening. This treatment introduces high compressive residual stresses near the surface that retard the initiation of cracks, but it also changes the microstructure and surface roughness. These residual stresses relax with the number of loading cycles. This paper experimentally studies the influence of the residual stresses and the surface condition on fretting fatigue life. To this end, in this work it is analysed the residual stress relaxation produced in fretting fatigue tests due to cycling loading. On the other hand, the effect produced by the characteristic shot peening surface roughness, is analysed by means of a series of tests in which surface's fretting test specimens are polished. In addition, experimental results obtained with fretting fatigue test specimens having a surface roughness resembling that obtained with shot peening, but without residual stress, and tests done with shot peened contact pads, are presented. In all cases, contact surfaces and fretting cracks are analysed in order to understand its fretting fatigue behaviour. Finally, a fatigue life model previously developed by the authors, but including the residual stress relaxation, is applied to the different set of tests obtaining good results. The paper concludes that shot peening greatly increases fatigue life, mainly for high-cycle fatigue. This improvement can be explained mainly through the stress distribution, with little influence of surface roughness.

Effect of initial surface treatment on shot peening residual stress field: Analytical approach with experimental verification

Shot peening is the most common surface treatment employed to enhance the fatigue performance of structural metallic materials and often carried out after other surface treatments. This paper mainly focuses on the effects of initial conditions of surface such as initial stress filed and hardness profile on shot peening residual stress field. The residual stress distribution induced by shot peening is obtained using Hertzian contact theory and elastic–plastic evaluation after yielding occurred during impingement and rebound of shots. Elastic plastic calculations are performed using different hardening models considering Bauschinger effect. The present model is able to predict redistribution of residual stresses in shot peening process by considering the initial conditions of target surface. Initial stress distribution and yield stress variation produced by previous surface treatments are taken into account by measuring residual stresses and hardness profile at near surface layers. An analytical parametric study is performed to evaluate the influence of initial conditions induced by surface pretreatments on shot peening residual stress field. The results of analytical model are validated by experimental data obtained in the literature as well as by our own measurements. The analytical results generally agree with the experimental measurements.

Probabilistic methodology for predicting the dispersionof residual stresses and Almen intensity considering shot peening process uncertainties

To ensure a high fatigue life and a reduced weight of automotive suspension system components, compressive residual stresses are commonly induced near the surface using many mechanical surface treatments. Among the most preferred techniques, shot peening process presents a high efficiency and a relative low cost. Nevertheless, the employment of such process is generally affected by many sources of variability. Indeed, the experimental residual stress measurements exhibit a significant variation from one component to another and even from different positions on the same component. Therefore, error bars are commonly used to quantify the variability of experimental residual stress measurements. Nevertheless, the majority of predictive approaches of residual stresses induced by shot peening do not consider the effect of the variability of shot peening process parameters. In this study, a probabilistic methodology is applied to evaluate the variability of the induced residual stress profile and the Almen intensity, regarding the scattering of the most significant shot peening process parameters. Furthermore, iso-probabilistic residual stress profile can be utilized to predict the shot peening residual stress profile with a specified probability of appearance.

Analytical modelling of shot-peening residual stress on welding carbon steel surface layer

The residual stress distribution was studied by an analytical model, due to shot peening on the welding carbon steel surface layer. The initial welding residual stresses before shot peening were taken into consideration in this analytical model. The Hertzian elastic contact theory was used to get the elastic compression stress state after impact on the surface layer. The initial welding stress field and the shot peening stress field would superpose and the welding surface layer would yield based on the elastic-plastic evaluation, then the residual stress after shot peening can be achieved. The influence of initial welding residual stress on the stress distribution after shot peening was analyzed and discussed. A series of experiments were carried out and the residual stress on the welding surface was determined by X-ray diffractometer before and after shot peening. The calculation results of the analytical model are consistent with the experimental results. The critical shot velocities when welding surface layer yielded and reverse yielded were calculated. While the welded joint surface material reversely yielded, the maximum compressive residual stress would not obviously increase with the increase of shot velocity, the thickness of the compressive stress layer would be increased. Welding residual tensile stress can enlarge the thickness of the compressive stress layer at the same shot velocity when reverse yield appeared.

Experimental measurement and analytical determination of shot peening residual stresses considering friction and real unloading behavior

This paper presents an analytical model to predict the residual stress distribution induced by Shot peening. The analytical approach is based on the work of Shen and Atluri (2006) [18] with some modifications. The modifications are related to the elasto-plastic unloading of shot impingements, friction coefficient effect and the fraction of kinetic energy transmitted to the treated material. In order to predict more realistic residual stresses, the elasto-plastic unloading phase of shot impacts is modeled using two nonlinear kinematic hardening models considering the Bauschinger effect. Moreover, the effect of the Coulomb friction between target surface and shots is evaluated. For this purpose, the interior stresses caused by tangential tractions of friction force are determined analytically. In this work, the effects of friction coefficient, hardening model in loading and unloading phases, the offset of determination of the yield points and the Bauschinger effect on the residual stress distribution are taken into account. Experiments are carried out on DIN 1.6582 medium carbon steel to validate the results obtained from the analytical model. The results of the comparison indicate that the analytical relations agree well with the experimental data.

Thermo-mechanical relaxation of compressive residual stresses induced by shot peening

Experimental and theoretical studies have shown that the compressive residual stresses induced by shot peening, have been identified, generally, as the principal factor for fatigue strength improvement. However, it is worth noticing, that the initial induced compressive shot peening residual stresses may be redistributed and relaxed under mechanical, thermal or thermo-mechanical cyclic loading. It is important to consider the relaxation phenomenon in the prediction of the fatigue behaviour of shot-peened parts. This paper presents a numerical approach to evaluate the mechanical, thermal and thermo-mechanical relaxation of the compressive residual stresses induced by shot peening.