Shot Peening Modeling and Simulation for RCS Assessment

Edward, Aghogho Bright; Heyns, P.S.; Pietra, Francesco

doi:10.1016/j.promfg.2016.12.044

Cited by 9 publications

(9 citation statements)

References 10 publications

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“…The proposed DEM-FEM coupling method of a large and real number of shots is an improvement of the method introduced by Jebahi and Gakwaya [ 15 ], Edward and Heyns [ 21 ] and Zhang and Lu [ 23 ]. The advantage of the improved method lies in the fact that the shot peening process is sequentially simulated without the need to extract the average equivalent induced stress to obtain the deformation indirectly.…”

Section: The Improved Dem–fem Approachmentioning

confidence: 99%

“…Bhuvaraghan and Srinivasan [ 4 ] used an FEM technique to model a slice of the Almen strip and captured its response behavior directly. Edward and Heyns [ 21 ] reported a simplified methodology for the simulation of the shot peening process and replaced the transient analysis with a simpler static structural analysis. Even though the existing numerical methods of Almen intensity can greatly reduce the cost and obtain more details that are difficult to find during the experiment, these simulation methods cannot directly simulate the Almen intensity, which is different from the real situation.…”

Section: Introductionmentioning

confidence: 99%

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An Improved Approach to Direct Simulation of an Actual Almen Shot Peening Intensity Test with a Large Number of Shots

et al. 2020

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In existing simulations of the Almen intensity test, arc height is indirectly obtained by an equivalent method including a representative cell, a few shots and equivalent loading. Most of these equivalent methods cannot consider the transverse deformation of the strip, the complex stress state of the plastic hardening layer and process parameters, resulting in deviation from the actual test. This paper introduces an improved and experimentally validated discrete element model (DEM)-finite element model (FEM) to predict the actual Almen intensity. The improvement of this model is mainly reflected in the large and real number of shots involved in the actual Almen intensity test, shot–shot interactions, and real-size solid finite element model of the Almen strip. A new method for calculating the shot stream is proposed based on the test and considering test process parameters such as the mass flowrate, nozzle movement speed and nozzle–workpiece distance. The shot stream impacting the strip with a fully restrained underside was first simulated in improved DEM-FEM to bring the forming energy. As a second step, an implicit solver of the Almen strip FEM calculates the spring-back to simulate strip removal from the holder. The results achieved by the present approach are compared with the results obtained by the experimental results and those in the literature. The results show that the arc height and Almen intensity obtained by the present approach match much better with the literature than the traditional method. Some new results obtained by the improved coupling DEM-FEM method are presented. The influences of the transverse deformation and surface plastic layer on the deformation of the Almen strip are discussed. This improved method provides an alternative characterization method for precision peen forming simulation.

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Section: The Improved Dem–fem Approachmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

An Improved Approach to Direct Simulation of an Actual Almen Shot Peening Intensity Test with a Large Number of Shots

et al. 2020

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“…Therefore, it is appropriate to use quasi-static models as an aid or complementary procedure dealing with static aspects of SP only. 23,29 For example, investigations done by Kang et al, 23 Sun and Zhang et al, 36 Gariepy et al 42 and Amarchinta et al 43 used static analysis after a dynamic procedure to rapidly stabilise the model so as to avoid the long computation procedure for dynamic analysis to reach a steady state. Edward et al 29 also used it in ANSYS software to save time as well and additionally to save hard disc space; and Frija et al 15 used it in the simplification of SP simulation models.…”

Section: Dynamic Explicit Versus Static Implicit Analysismentioning

confidence: 99%

Literature review of numerical simulation and optimisation of the shot peening process

Chen

Desai

Heyns

et al. 2019

Advances in Mechanical Engineering

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This work provides a comprehensive review of numerical simulation and optimisation of the shot peening found in the existing literature over the past 10 years. The review found that the developed numerical models coupling finite elements with discrete elements became increasingly mature and showed their advantages in incorporating flow behaviour and randomness of shots. High emphasis must be placed on the constitutive equations of target material where its strain-rate sensitivity, cyclic behaviour and Bauschinger effects are recommended to be incorporated in the numerical material model simultaneously since considering one of them in isolation may lead to unreliable distribution of residual stresses. Furthermore, material hardening is a critical benefit of shot peening; however, it has not received its deserved attention from the existing investigations, neither in simulation nor in optimisation. The study found that intensity and coverage are two critical control parameters recommended to be constraints for optimisation of shot peening. Finally, this work also found that developed heuristic algorithms, such as genetic algorithms have recently showed their advantages for searching optimal combinations of peening parameters. It is plausible that in the near future, the synergy of combining these algorithms with approximation models can be expected to gain more attention by researchers.

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“…In light of the above discussions, this paper is aimed at enhancing the DEM-FEM approach previously developed by Edward et al [33] for a simplified numerical simulation of a realistic SP process. This is needed in order to set the stage for developing a numerical framework that captures all the relevant shot parameters that are of industrial relevance while maintaining the principles of impact mechanics in the SP process simulation.…”

Section: Introductionmentioning

confidence: 99%

“…The main objective of this paper is to establish the basis for a proposed DEM-FEM framework [33] needed to simulate a realistic SP process, by means of single-shot impact analysis from an applied mechanics perspective. This approach utilizes the plastic strain energy component of a single-shot impact, as opposed to the reactive contact force component utilized by previous work [28].…”

Section: Introductionmentioning

confidence: 99%

A Numerical Investigation of a Single-Shot in a DEM-FEM Approach to Shot Peening Simulation

Edward

Heyns

Kok

2019

Metals

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Shot peening (SP) is a controlled and systematic process of surface treatment that has a large number of controllable process parameters that make its application highly challenging. It involves the shooting of small and hard metallic balls at a targeted surface, with the aim of enhancing the fatigue strength of the workpiece under unfavorable service conditions. The compressive residual stress (CRS) induced by this application is expensive to evaluate experimentally. This paper presents a numerical model of the impact of a single-shot on a metallic surface, with the aim to set the stage for a realistic multiple shots peening simulation. The approach proposed herein is a sequential Discrete Element-Finite Element (DE-FE) coupled simulation, based on the use of different types of coefficients of restitution (CoRs) with emphasis on the energetic CoR. The energetic CoR relates the shot/target contact forces to the fractional strain energy needed for localized plastic deformation of the near-surface layer in the workpiece. The generated results of the induced compressive residual stresses (CRS) and equivalent plastic strain (PEEQ) from single-shot simulations are validated with similar results from the literature. Our study clarifies the strain energy aspects of a single-shot impact responsible for the desired effects of CRS and PEEQ, thereby laying the groundwork for accurate and realistic modeling of the SP process via the DEM-FEM approach.

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Shot Peening Modeling and Simulation for RCS Assessment

Cited by 9 publications

References 10 publications

An Improved Approach to Direct Simulation of an Actual Almen Shot Peening Intensity Test with a Large Number of Shots

An Improved Approach to Direct Simulation of an Actual Almen Shot Peening Intensity Test with a Large Number of Shots

Literature review of numerical simulation and optimisation of the shot peening process

A Numerical Investigation of a Single-Shot in a DEM-FEM Approach to Shot Peening Simulation

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