Effects of Conventional and Severe Shot Peening on Residual Stress and Fatigue Strength of Steel AISI 1060 and Residual Stress Relaxation Due to Fatigue Loading: Experimental and Numerical Simulation

Maleki, Erfan; Farrahi, G.H.; Kashyzadeh, Kazem Reza; Ünal, Okan; Gugaliano, Mario; Bagherifard, Sara

doi:10.1007/s12540-020-00890-8

Cited by 57 publications

(14 citation statements)

References 37 publications

(36 reference statements)

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“…7, the FWHM values at the topmost surface for (110) lattice plane increase with coverage levels, and the value of SP40 increases by 32.16% compared with that of SP1. The grain size is negatively correlated with FWHM [52]. Hence, it is revealed that with the increase of coverage, grain size at the topmost surface decreases, whereas FWHM becomes wider.…”

Section: Phase Analysismentioning

confidence: 82%

Determination of the optimal coverage for heavy-duty-axle gears in shot peening

Yan

Zhu

Chen

et al. 2021

Int J Adv Manuf Technol

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Pitting and wear often appear on heavy-duty-axle gears due to their harsh working conditions, such as high torques, high loads and poor lubrication. Shot peening is a popular surface strengthening method for gears. In order to ensure complete coverage during shot peening, 100%~200% coverage is usually prescribed for most gears. However, it is difficult to effectively improve the contact fatigue and wear resistance of heavy-duty-axle gears. Generally, increasing shot peening coverage can heighten the compressive residual stress for prolonging the service lifetime of gears. Whereas, high coverage levels may cause the deterioration of surface roughness, thus increase the noise and vibration of gears. To address this issue, this paper deals with the determination of optimal coverage for heavy-duty-axle gears by experimental tests. The influence of shot peening coverage on the surface integrity of gears is analyzed in terms of residual stress, microhardness, surface morphology and dislocation density. The results show that the maximum compressive residual stress increases first and then keeps stable with the increase of coverage, and the maximum value is −1172.10 MPa. The microhardness peak increases obviously in the beginning and then slowly rises with the increase of coverage, and the maximum value is 747.5 HV1.0. The surface roughness (Ra) decreases initially and then enhances with the increase of coverage, and the minimum value is 0.99 μm under the coverage of 1000%. The dislocation density increases with the increase of coverage, and the maximum value is 3.70×10 16 m -2 . Numerous damages (microscalings, spallings) occur on the treated gear tooth flank affecting the residual stress distribution and roughness under high coverage levels. Taking into consideration of service lifetime, working noise and economic efficiency, the coverage of 1000% is the optimal coverage for heavy-duty-axle gears in shot peening.

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Section: Phase Analysismentioning

confidence: 82%

Determination of the optimal coverage for heavy-duty-axle gears in shot peening

Yan

Zhu

Chen

et al. 2021

Int J Adv Manuf Technol

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“…On the other hand, artificial intelligence (AI) based methods such as neural networks (NN) are remarkably applied in different aspects of science and engineering [26][27][28][29], as well as their applications in fatigue behavior prediction and analysis [30][31][32][33][34][35] and modelling of SP process [28,30,[36][37][38]. In general, a neural network has three major layers of input, hidden and output [39].…”

Section: Introductionmentioning

confidence: 99%

Analysing the Fatigue Behaviour and Residual Stress Relaxation of Gradient Nano-Structured 316L Steel Subjected to the Shot Peening via Deep Learning Approach

et al. 2021

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In this study, the effect of kinetic energy of the shot peening process on microstructure, mechanical properties, residual stress, fatigue behavior and residual stress relaxation under fatigue loading of AISI 316L stainless steel were investigated to figure out the mechanisms of fatigue crack initiation and failure. Varieties of experiments were applied to obtain the results including microstructural observations, measurements of hardness, roughness, induced residual stress and residual stress relaxation as well as axial fatigue test. Then deep learning approach through neural networks was used for modelling of mechanical properties and fatigue behavior of shot peened material. Comprehensive parametric analyses were performed to survey the effects of different key parameters. Afterward, according to the results of neural network analysis, further experiments were performed to optimize and experimentally validate the desirable parameters. Based on the obtained results the favorable range of shot peening coverage regarding improved mechanical properties and fatigue behavior was identified as no more than 1750% considering Almen intensity of 21 A (0.001 inch). Graphic abstract

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“…Surface strengthening by different severe plastic deformation (SPD) methods has been widely perceived to enhance surface mechanical properties [1]. Researchers have used SPD by shot peening [2,3], severe shot peening (SSP) [4,5], ultrasonic impact peening [6,7], ultrasonic shot peening (USP) [8,9], laser shock peening [10,11], direct and indirect laser shock surface patterning (LSSP) [12,13], surface mechanical attrition treatment (SMAT) [14,15], and deep cold rolling (DCR) [16]. These surface SPD techniques could induce residual compressive stress (RCS) and closure of existing microcracks and microcavities on the surface [17][18][19][20].…”

Section: Introductionmentioning

confidence: 99%

Ultrasonic Surface Rolling Process: Properties, Characterization, and Applications

et al. 2021

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Ultrasonic surface rolling process (USRP) is a novel surface severe plastic deformation (SPD) method that integrates ultrasonic impact peening (UIP) and deep rolling (DR) to enhance the surface integrity and surface mechanical properties of engineering materials. USRP can induce gradient nanostructured surface (GNS) layers on the substrate, providing superior mechanical properties, thus preventing premature material failure. Herein, a comprehensive overview of current-state-of-the art USRP is provided. More specifically, the effect of the USRP on a broad range of materials exclusively used for aerospace, automotive, nuclear, and chemical industries is explained. Furthermore, the effect of USRP on different mechanical properties, such as hardness, tensile, fatigue, wear resistance, residual stress, corrosion resistance, and surface roughness are summarized. In addition, the effect of USRP on grain refinement and the formation of gradient microstructure is discussed. Finally, this study elucidates the application and recent advances of the USRP process.

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Effects of Conventional and Severe Shot Peening on Residual Stress and Fatigue Strength of Steel AISI 1060 and Residual Stress Relaxation Due to Fatigue Loading: Experimental and Numerical Simulation

Cited by 57 publications

References 37 publications

Determination of the optimal coverage for heavy-duty-axle gears in shot peening

Determination of the optimal coverage for heavy-duty-axle gears in shot peening

Analysing the Fatigue Behaviour and Residual Stress Relaxation of Gradient Nano-Structured 316L Steel Subjected to the Shot Peening via Deep Learning Approach

Ultrasonic Surface Rolling Process: Properties, Characterization, and Applications

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