| WANG Changqing,ZHANG Huiyun,TANG Jinyuan,ZHAO Jiuyue,LYU Liangliang.Numerical Research and Experimental Investigation of Residual Stress and Roughness of Double Helical Gear after Shot Peening[J],54(5):245-256 |
| Numerical Research and Experimental Investigation of Residual Stress and Roughness of Double Helical Gear after Shot Peening |
| Received:March 26, 2024 Revised:September 04, 2024 |
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| DOI：10.16490/j.cnki.issn.1001-3660.2025.05.019 |
| KeyWord:double helical gear shot peening residual stress roughness discrete element method finite element method |
| Author | Institution |
| WANG Changqing |
AECC Harbin Dongan Engine Co., Ltd., Harbin , China |
| ZHANG Huiyun |
State Key Laboratory of High-Performance Complex Manufacturing, Central South University, Changsha , China |
| TANG Jinyuan |
State Key Laboratory of High-Performance Complex Manufacturing, Central South University, Changsha , China |
| ZHAO Jiuyue |
State Key Laboratory of High-Performance Complex Manufacturing, Central South University, Changsha , China |
| LYU Liangliang |
State Key Laboratory of High-Performance Complex Manufacturing, Central South University, Changsha , China |
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| Abstract: |
| The work aims to investigate the effect of shot peening process parameters on residual stress and roughness of double helical gear. In order to more realistically approach the actual shot peening process, a discrete element shot peening model is established. DEM model is used to simulate the information after the shot is injected from the nozzle to the impact of the tooth surface, so as to simulate the actual complex shot peening process. Then, the information such as the position and velocity of the shot impacting the tooth surface is obtained. The impact information of DEM model is obtained, which is input into the finite element model as the initial conditions. The shot in the finite element model continuously impacts the surface of the target plate with the calculation results of the DEM model and the residual stress and surface topography calculated by the finite element model are extracted by the Python program. The calculated residual stress and surface morphology are characterized and it is found that the maximum calculation error is less than 15%, which indicates that the calculation results have good accuracy. It is found that the shot velocity increases from 40 m/s to 60 m/s and the surface residual compressive stress in the tooth width direction increases from ‒906 MPa to ‒932 MPa. When the shot diameter increases from 0.3 mm to 0.6 mm, the surface residual stress in the direction of tooth width decreases from ‒906 MPa to ‒756 MPa. However, the maximum residual compressive stress increases with the increase of shot diameter and velocity. When the coverage is less than 100%, both Sa and residual comprehensive stress increase rapidly. When the coverage exceeds 100%, both Sa and increase rate of residual comprehensive stress begin to decrease. The above results show that, due to the complex curved structure of double helical gear, the residual stress levels in the tooth width and tooth height are different even though the impact times are almost the same in the tooth surfaces with different rotation directions. With the increase of shot velocity and shot diameter, the maximum residual compressive stress will increase. However, the increase in the diameter and velocity of the shot will deteriorate the surface quality of the part. Therefore, in the actual shot peening process, it can be considered to firstly use a large size shot to obtain a deeper residual stress qualitative change layer and then use a small size shot to improve the surface quality of the part. The coverage is an important parameter and when the coverage increases to a certain extent, the residual stress level and surface quality of the material will tend to be stable. Therefore, reasonable control of coverage can improve the efficiency of processing and reduce the cost. |
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