| CHEN Sheng,DING Teng-fei,ZHANG Chao-yang,GAO Jian-yong,FU Jing-yi,LU Shi-hong.An Efficient Approach in Numerical Simulation of Shot Peening[J],52(8):458-465 |
| An Efficient Approach in Numerical Simulation of Shot Peening |
| Received:August 10, 2022 Revised:November 22, 2022 |
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| DOI：10.16490/j.cnki.issn.1001-3660.2023.08.042 |
| KeyWord:shot peening numerical simulation SAE 1070 shot distance induced stress |
| Author | Institution |
| CHEN Sheng |
College of Mechanical & Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing , China |
| DING Teng-fei |
College of Mechanical & Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing , China |
| ZHANG Chao-yang |
Shandong Kaitai Shot Blasting Machinery Share Co., Ltd., Shandong Binzhou , China |
| GAO Jian-yong |
Shandong Kaitai Shot Blasting Machinery Share Co., Ltd., Shandong Binzhou , China |
| FU Jing-yi |
College of Mechanical & Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing , China |
| LU Shi-hong |
College of Mechanical & Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing , China |
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| Abstract: |
| Shot peening is a mechanical surface enhancement process widely used in the automotive and aerospace industry. The residual stress, as the main response parameter, plays an important role in improving the fatigue life of components. Compared with the costly and time-consuming experimental measurement, numerical simulation provides great convenience for the research of residual stress state, revealing mechanism and process optimization. Among them, the random multi-shot model can truly reflect the shot peening process, but it often faces the problem of high calculation cost, which limits the application of related technical methods. The shot peening model was established in Abaqus/Explicit in this paper. Therefore, from the perspective of increasing the spatial distribution density of shots to reduce the analysis step time, the distance and distribution mode of random shots were adjusted to study a simulation method that not only improved the calculation efficiency but also took into account the accuracy. Taking SAE1070 spring steel as the research object, the velocity of S230 shots was 40 m/s and the number of shots was 150 (not reaching full coverage). The shots were distributed in layers, and eight groups of different vertical distances between layers (0, 0.005, 0.01, 0.03, 0.05, 0.07, 0.3 and 0.6 mm) and six groups of different horizontal distances of shots in the same layer (>0.1, >0.2, >0.3, >0.4, >0.5 and >0.6 mm) were set respectively. Then, the effects of vertical distances and horizontal distances between shots on simulation results were analyzed. On this basis, the simultaneous impact and sequential impact of 150 and 300 shots were simulated, and the effect of shots impact mode on simulation results was analyzed. Then, according to the above research scheme, the distribution mode of shots was determined under different diameters and velocities, and a 1/4 Almen strip model based on real size was established. In the simulation, the number of shots was accumulated by data transfer between models, and an implicit solver was used to calculate the arc height of the spring-back strips under different numbers of shots, and the Almen intensity was obtained. Finally, the results achieved by the present approach were compared with those obtained in the literature. The results showed that, without considering the interaction between the shots, the shots could overlap in the finite element simulation, as long as the vertical distance was larger than 0.07 mm and the horizontal distance was larger than 0.4 mm, the results of induced stress distribution, plastic strain distribution and roughness obtained by simulation tended to be consistent, and under the premise of meeting the shots distance threshold, the results of induced stress distribution obtained by simultaneous impact and sequential impact were almost the same. Moreover, the calculation time was shortened by about 90%, which meant that it was more efficient to simulate the stress distribution of shot peening by simultaneous impact. Shot peening simulations of Almen strips demonstrated that Almen intensity obtained by the present approach matched much better with the literature. In addition, the results showed that the greater the kinetic energy of the same kind of shots, the less number of shots needed to reach the saturation point, and high coverage had no significant effect on the arc height. This approach of setting shots with simultaneous impact by layer distribution and reducing the distance between shots on the premise of satisfying the distance threshold improves the calculation efficiency, ensures the simulation accuracy of the stress state, is suitable for the simulation of shot peening and deformation of the slightly larger target, and provides a new idea to optimize the calculation cost for the application of numerical simulation. |
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