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Multibody modeling of the shot peening process

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Abstract

Shot peening is a mechanical process in which a component surface is subjected to the collision of thousands of small steel shots so inducing a compressive residual stress field that improves its fatigue resistance. Conventional numerical techniques, such as finite element method, are prohibitive to model the entire behavior of the media stream over the entire treated component because of the high computational cost. An alternative is to base such an analysis on the rigid body mechanics. Here, a multibody system approach was used to model the global shot peening process when applied on a leaf spring. Two thousands shot spheres impelled by a two-wheel peening machine were included in the model. Both dimensions and peening parameters were extracted from an experimental test developed also in this study. Graphical results allowed finding out some important aspects as the media trajectories, media interference, and the identification of the high peening intensity points. All these aspects resulted to be important for evaluating the peening arrangement efficacy. In addition, the media velocity and the peening coverage, both indispensables to assess the treatment of the peened component, were also obtained.

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Abbreviations

a c :

Centrifugal acceleration of the media, m s−2

B :

Length of the wheel blade, mm

d :

Diameter of the media, mm

d i :

Average diameter of the media indentation, mm

d 0 :

Diameter of the reference shot media, mm

C :

Peening coverage, %

C A :

Peening coverage for area coverage model, %

C L :

Peening coverage for linear coverage model, %

D ind :

Shot indentation diameter, mm

flux:

Media flux, m−1s−1

F 0 :

Media flux constant, s−1

f A :

Almen intensity, mm

k :

Correction factor of radial velocity due to friction, dimensionless

L :

Length unit, m

n :

Density of media indentations, m−1 and m−2 (for linear and area coverage models)

n sat :

Density of media indentations to reach saturation, m−1 and m−2 (for linear and area coverage models)

N :

Number of media indentations, dimensionless

r :

Radial distance from the center of the peening wheel, m

R :

Radius of the peening wheel, mm

t :

Time, s

T :

Time of peening exposure, s

T sat :

Time of peening exposure to reach saturation, s

v c :

Chain conveyor velocity, m min−1

v r :

Radial velocity of the media, m s−1

v t :

Tangential velocity of the media, m s−1

V R :

Radial velocity of the media when reaching the wheel perimeter, m s−1

V S :

Total velocity of the media when reaching the wheel perimeter, m s−1

V T :

Tangential velocity of the media when reaching the wheel perimeter, m s−1

x :

Coordinate in the horizontal direction of the model, m

y :

Coordinate in the vertical direction of the model, m

ΦAt :

Flux constant for the area coverage model dependent on the peening time, m−2 s−1

ΦLt :

Flux constant for the linear coverage model dependent on the peening time, m−1 s−1

ΦAn :

Flux constant for the area coverage model dependent on the number of media impingements, m−2

ΦLn :

Flux constant for the linear coverage model dependent on the number of media impingements, m−1

υ :

Locations of first media flux peak, m

μ :

Locations of second media flux peak, m

σ :

Standard deviation, m

σ y :

Yield stress of the peened material (SAE-5160 steel), MPa

\( \sigma_{\text{y}}^{\text{ref}} \) :

Yield stress of the reference material (SAE-1070 steel), MPa

ω :

Wheel rotational velocity, s−1

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Authors and Affiliations

  1. Department of Mechatronics and Mechanical Systems Engineering, Polytechnic School of the University of Sao Paulo, Sao Paulo, SP, 05508-900, Brazil

    Miguel A. G. Calle & Marcílio Alves

Authors
  1. Miguel A. G. Calle
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  2. Marcílio Alves
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Correspondence to Miguel A. G. Calle.

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Technical Editor: Alexandre Abrão.

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Calle, M.A.G., Alves, M. Multibody modeling of the shot peening process. J Braz. Soc. Mech. Sci. Eng. 36, 111–124 (2014). https://doi.org/10.1007/s40430-013-0068-0

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  • DOI: https://doi.org/10.1007/s40430-013-0068-0

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