Numerical modeling of residual stresses during vibratory peening of a 3-stage Blisk – a multi-scale discrete element and finite element approach

Alcaraz, Joselito Yam; Zhang, Jing; Nagalingam, Arun Prasanth; Gopasetty, Sharan Kumar; Toh, Boon Loong; Gopinath, Abhay; Ahluwalia, K. S.; Ang, Marcus Guo Wei; Yeo, Song Huat

doi:10.1016/j.jmatprotec.2021.117383

Cited by 23 publications

(11 citation statements)

References 26 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Thus, the resulting stress concentration factor is only 1.04 using 20-node quadratic brick elements with reduced integration in Abaqus; see Figure 4b. As the CNC-driven milling process produces sharp edges, specimens were additionally polished by a vibratory finishing process [66][67][68][69]. Thereby, the specimens were ground and polished with different abrasive media to obtain the required surface quality.…”

Section: Methodsmentioning

confidence: 99%

A Probabilistic Fatigue Strength Assessment in AlSi-Cast Material by a Layer-Based Approach

Oberreiter

Fladischer

Stoschka

et al. 2022

Metals

View full text Add to dashboard Cite

An advanced lightweight design in cast aluminium alloys features complexly shaped geometries with strongly varying local casting process conditions. This affects the local microstructure in terms of porosity grade and secondary dendrite arm spacing distribution. Moreover, complex service loads imply changing local load stress vectors within these components, evoking a wide range of highly stressed volumes within different microstructural properties per load sequence. To superimpose the effects of bulk and surface fatigue strength in relation to the operating load sequence for the aluminium alloy EN AC 46200, a layer-based fatigue assessment concept is applied in this paper considering a non-homogeneous distribution of defects within the investigated samples. The bulk fatigue property is now obtained by a probabilistic evaluation of computed tomography results per investigated layer. Moreover, the effect of clustering defects of computed tomography is studied according to recommendations from the literature, leading to a significant impact in sponge-like porosity layers. The highly stressed volume fatigue model is applied to computed tomography results. The validation procedure leads to a scattering of mean fatigue life from −2.6% to 12.9% for the investigated layers, inheriting strongly varying local casting process conditions.

show abstract

Section: Methodsmentioning

confidence: 99%

A Probabilistic Fatigue Strength Assessment in AlSi-Cast Material by a Layer-Based Approach

Oberreiter

Fladischer

Stoschka

et al. 2022

Metals

View full text Add to dashboard Cite

show abstract

“…Another variation of shot peening is vibratory shot peening. In the vibratory shot peening process, workpieces and shot peening elements (usually steel balls) are placed in a working chamber which performs oscillating motion [6,7].…”

Section: Introductionmentioning

confidence: 99%

Study on selected properties of the surface layer of magnesium alloys after impulse shot peening

Skoczylas,

Zaleski,

Ciecieląg

et al. 2024

Preprint

View full text Add to dashboard Cite

Shot peening is a commonly used method of finishing machine elements in the manufacturing process. One variation of shot peening is the impulse shot peening. This paper presents the influence of impulse shot peening technological conditions on the surface roughness (parameters Ra and Rt) and topography, microhardness. The FEM was used to determine the S11 stresses. In the experiment and simulation tests, AZ31 and AZ91HP magnesium alloy samples were used. Variable parameters in the impulse shot peening process were: impact energy E: 15 ÷ 185 mJ, ball diameter d: 3 ÷ 15 mm and impact density j: 3 ÷ 44 mm− 2. As a result of the tests carried out, it was found that after impulse shot peening, the surface topography is change, microirregularities are flattened, numerous depressions are formed, which can be potential lubrication pockets. The 2D surface roughness parameters for most impulse shot peening conditions are lower than for the pre-machining. The roughness parameters for magnesium alloy AZ91HP are lower than for AZ31. This is most likely due to the lower elongation A. The microhardness after impulse shot peening increased by 20 HV to 87 HV. As a result of FEM of the impulse shot peening, compressive stresses S11 were created in the surface layer. The depth of occurrence of S11 stresses is from 1.5 to 3.5 mm, and their value for the AZ91HP magnesium alloy samples are 10–25% lower than for the AZ31 alloy samples. The most favorable results of the tested properties of the surface layer were obtained for E = 100 mJ, d = 10 mm, j = 11 mm− 2.The abstract serves both as a general introduction to the topic and as a brief, non-technical summary of the main results and their implications.

show abstract

“…In recent years, researchers have utilized DEM to investigate the mechanisms of vibratory polishing, with a particular focus on understanding the role of particle-particle and particle-wall interactions in the process. 15 One of the key challenges in modeling vibratory polishing with DEM is accurately capturing the complex interactions between particles and the bowl walls. Researchers have developed various contact models that consider the shape and material properties of the bowl and the particles.…”

Section: Introductionmentioning

confidence: 99%

Effect of In-trough and Out-of-trough fixturing in vibro-polishing

Yuvaraj

Gopasetty

Nagalingam

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

Self Cite

View full text Add to dashboard Cite

Advanced compressor design with superior aerodynamic and fatigue life performance demands superior surface quality, typically Ra≤0.25 µm. Vibro-polishing is media finishing technology which is commonly employed to mass finish aerospace engine components such as blisks. Frequency of vibration, location, and orientation of workpiece, media size, lubrication etc. are known tuneable knobs to optimize the performance of Vibro-polishing. However, longer cycle times in vibro-polishing still pose a challenge. In this study, effect of In-trough (IT) and Out of trough (OOT) fixturing at various depths of immersion into the media is studied. Workpiece used was made of Ti-6Al-4V with a geometry representative of a blisk blade. OOT fixturing was observed to yield better surface quality than IT fixturing irrespective of the depth of immersion. Further, a very low Ra of about 0.10 µm was achieved with 1 h of processing at highest depth of immersion into the media in OOT fixturing, resulting in significant reduction in cycle time to reach aerospace component surface roughness of Ra≤0.25 µm. Further, uniform vibro-polished surface topography with no alterations in the as received microstructure was observed in both IT and OOT fixturing.

show abstract

Numerical modeling of residual stresses during vibratory peening of a 3-stage Blisk – a multi-scale discrete element and finite element approach

Cited by 23 publications

References 26 publications

A Probabilistic Fatigue Strength Assessment in AlSi-Cast Material by a Layer-Based Approach

A Probabilistic Fatigue Strength Assessment in AlSi-Cast Material by a Layer-Based Approach

Study on selected properties of the surface layer of magnesium alloys after impulse shot peening

Effect of In-trough and Out-of-trough fixturing in vibro-polishing

Contact Info

Product

Resources

About