scholarly journals A FEM-Based 2D Model for Simulation and Qualitative Assessment of Shot-Peening Processes

Materials ◽  
2021 ◽  
Vol 14 (11) ◽  
pp. 2784
Author(s):  
Georgios Maliaris ◽  
Christos Gakias ◽  
Michail Malikoutsakis ◽  
Georgios Savaidis
Keyword(s):  
Process Parameters ◽  
Material Properties ◽  
Shot Peening ◽  
Qualitative Assessment ◽  
Experimental Investigations ◽  
Elastoplastic Material ◽  
Size Distributions ◽  
User Friendly ◽  
The Impact ◽  
2D Model

Shot peening is one of the most favored surface treatment processes mostly applied on large-scale engineering components to enhance their fatigue performance. Due to the stochastic nature and the mutual interactions of process parameters and the partially contradictory effects caused on the component’s surface (increase in residual stress, work-hardening, and increase in roughness), there is demand for capable and user-friendly simulation models to support the responsible engineers in developing optimal shot-peening processes. The present paper contains a user-friendly Finite Element Method-based 2D model covering all major process parameters. Its novelty and scientific breakthrough lie in its capability to consider various size distributions and elastoplastic material properties of the shots. Therewith, the model is capable to provide insight into the influence of every individual process parameter and their interactions. Despite certain restrictions arising from its 2D nature, the model can be accurately applied for qualitative or comparative studies and processes’ assessments to select the most promising one(s) for the further experimental investigations. The model is applied to a high-strength steel grade used for automotive leaf springs considering real shot size distributions. The results reveal that the increase in shot velocity and the impact angle increase the extent of the residual stresses but also the surface roughness. The usage of elastoplastic material properties for the shots has been proved crucial to obtain physically reasonable results regarding the component’s behavior.

Modelling of the Ultrasonic Shot Peening Process

2005 ◽  
Vol 490-491 ◽  
pp. 67-72 ◽  
Author(s):  
C. Pilé ◽  
Manuel François ◽  
Delphine Retraint ◽  
Emmanuelle Rouhaud ◽  
Jian Lu
Keyword(s):  
Process Parameters ◽  
Vibration Frequency ◽  
Shot Peening ◽  
Boltzmann Distribution ◽  
Perfect Gas ◽  
Average Speed ◽  
Speed Distribution ◽  
Almen Intensity ◽  
Ultrasonic Shot Peening ◽  
The Impact

The aim of this work is to reach a better understanding of the ultrasonic shot-peening process and, in particular, the evolution of the shot speed distribution. A simple 1D modelling of the interaction between the shots and the sonotrode is carried out. The impact is considered as inelastic with an energy absorption that depends on the speed of the shot. It is found that after about 10 interactions (» 1s) the speed distribution in the chamber follows a Maxwell-Boltzmann distribution, which is the distribution found in a perfect gas at equilibrium. The influence of various process parameters such as the sonotrode amplitude, the vibration frequency on the average speed and on the Almen intensity is studied.

Approach by Simulation of Residual Stress Generated by Shot-Peening and Their Stability during Fatigue Cycling

2011 ◽  
Vol 681 ◽  
pp. 303-308
Author(s):  
H. Michaud ◽  
Jean Michel Sprauel ◽  
Chedly Braham
Keyword(s):  
Residual Stress ◽  
Process Parameters ◽  
Shot Peening ◽  
Low Cycle Fatigue ◽  
Fatigue Behaviour ◽  
X Ray Diffraction ◽  
Alloy Steels ◽  
Spring Leaf ◽  
Usual Process ◽  
The Impact

ASCOMETAL produces alloy steels used for spring (leaf or coil), where the weak fatigue points are on the surface which is reinforced by shot-peening. So, the fatigue optimization with the steel grade needs a perfect knowledge of the material answer after shot-peening. For that reason, an analytical model has been developed where low cycle fatigue behaviour and all the usual process parameters are integrated (especially the impact position, and the covering-rate). Moreover, through a Monte-Carlos approach, the model permits to analyse the effect of scattering elements like impact speeds, ball sizes, or material fatigue behaviour. With this model several key process parameters have been analysed and validated with residual stress profiles evaluated by X-ray diffraction. So, for spring leaf, the effect of an applied load during shot-peening or shakedown during bending fatigue is described.

scholarly journals Influence of the Energy Density for Selective Laser Melting on the Microstructure and Mechanical Properties of Stainless Steel

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 919 ◽  
Author(s):  
Črtomir Donik ◽  
Jakob Kraner ◽  
Irena Paulin ◽  
Matjaž Godec
Keyword(s):  
Mechanical Properties ◽  
Stainless Steel ◽  
Energy Density ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
Material Properties ◽  
Beam Diameter ◽  
Laser Melting ◽  
Microstructure And Mechanical Properties ◽  
The Impact

We have investigated the impact of the process parameters for the selective laser melting (SLM) of the stainless steel AISI 316L on its microstructure and mechanical properties. Properly selected SLM process parameters produce tailored material properties, by varying the laser’s power, scanning speed and beam diameter. We produced and systematically studied a matrix of samples with different porosities, microstructures, textures and mechanical properties. We identified a combination of process parameters that resulted in materials with tensile strengths up to 711 MPa, yield strengths up to 604 MPa and an elongation up to 31%, while the highest achieved hardness was 227 HV10. The correlation between the average single-cell diameter in the hierarchical structure and the laser’s input energy is systematically studied, discussed and explained. The same energy density with different SLM process parameters result in different material properties. The higher energy density of the SLM produces larger cellular structures and crystal grains. A different energy density produces different textures with only one predominant texture component, which was revealed by electron-backscatter diffraction. Furthermore, three possible explanations for the origin of the dislocations are proposed.

Experimental investigations on the impact of bond process parameters in two-dimensional ultrasonic copper bonding

2018 ◽  
Author(s):  
Collin Dymel ◽  
Reinhard Schemmel ◽  
Tobias Hemsel ◽  
Walter Sextro ◽  
Michael Brokelmann ◽  
...  
Keyword(s):  
Process Parameters ◽  
Experimental Investigations ◽  
Two Dimensional ◽  
The Impact

Robust Design for Fatigue Performance: Shot Peening

1996 ◽  
Author(s):  
Marcos Esterman ◽  
Ivan M. Nevarez ◽  
Kosuke Ishii ◽  
Drew V. Nelson
Keyword(s):  
Fatigue Life ◽  
Surface Treatment ◽  
Robust Design ◽  
Process Parameters ◽  
Material Properties ◽  
Shot Peening ◽  
Fatigue Performance ◽  
Quality Characteristic ◽  
Design Parameters ◽  
Line Production

Abstract Fatigue data usually display substantial scatter. The goal of this paper is to demonstrate how simulated variation in surface treatment processing parameters and material properties affect the predicted fatigue life (mean and scatter) of a component. This is achieved by applying robust design principles to fatigue life evaluation methods, using shot peening as the representative manufacturing process for this study. Analyzing changes in the appropriate fatigue performance quality characteristic due to variations in the process parameters and material properties will identify levels of the controllable process parameters which maximize the mean fatigue performance and minimize its scatter. The simulation predictions of this study are consistent with past experimental observations which show that compressive residual stress distributions tend to increase mean fatigue life and reduce its scatter for a component. Our results extend these observations by relating the increase in mean life and the reduction in scatter to the controllable manufacturing and design parameters. In addition, the intermediate measure of compressive zone depth is identified as a possible off-line production quality check that relates directly to the component fatigue performance (mean and scatter), as well as an aid to the designer to identify an appropriate surface treatment process. This study serves as an initial step in the development of a generalized methodology that can aid engineers with design for robust fatigue performance for other manufacturing processes.

scholarly journals INFLUENCE OF FORCE OF INERTIA ON COATING CLUTCH WITH EXTERNAL SURFACE OF ROTATION BODIES WHEN COATING

2020 ◽  
Vol 2020 (5) ◽  
pp. 4-11
Author(s):  
Aleksey Rodichev ◽  
Andrey Gorin ◽  
Mariya Tokmakova ◽  
Alesey Kirichek
Keyword(s):  
Adhesion Strength ◽  
Outer Surface ◽  
Qualitative Assessment ◽  
Experimental Investigations ◽  
Strength Increase ◽  
Test Machine ◽  
Antifriction Coating ◽  
Coating Application ◽  
Qualitative And Quantitative ◽  
The Impact

A paper is dedicated to the investigation of inertia impact upon coating adherence with the outer surface of revolution solids during coating application. The work purpose is a qualitative and qualitative assessment of factors of antifriction coating application affecting the parts of friction units of machines and units. The relevance is substantiated with that the strength increase of coating applied ensures life, reliability and power effectiveness of machines and mechanisms. The work novelty consists in the application of fundamental dependences and laws to actual manufacturing operations. Adhesion is a basic parameter charactering quality of the coating applied. Adhesion, in its turn, is characterized with adhesion strength and porosity of the coating applied. The material presented shows the impact of inertia acting upon particles of the coating applied at their falling on the outer surface of rotation. There are defined theoretical dependences describing the process mentioned. The analysis of these dependences shows that inertia can carry out both the positive and negative action during the application of antifriction coatings. To confirm the theoretical results obtained there were carried out experimental investigations. In the experiment took part some sets of samples upon which PRNH17SR4 antifriction coating was applied. Coating application was carried out with the aid of the Iskra-1 burner with the further fusing. For the qualitative and quantitative strength assessment of adhesion of the coating applied there was used a method for a shear test. The samples prepared were pressed through a matrix on the GMS-50 universal rupture-test machine. As a result of tests carried out there are obtained dependences characterizing adhesion of antifriction coating applied. The dependences obtained show efficient factors impacting the adhesion strength of coatings. By the results of theoretical and experimental investigations there are formulated qualitative and quantitative assessments of factors influencing the process of antifriction coating application on parts.

scholarly journals Design and Development of a Computational Tool for a Dialyzer by Using Computational Fluid Dynamic (CFD) Model

Membranes ◽  
2021 ◽  
Vol 11 (12) ◽  
pp. 916
Author(s):  
Tuba Yaqoob ◽  
Muhammad Ahsan ◽  
Sarah Farrukh ◽  
Iftikhar Ahmad
Keyword(s):  
Process Parameters ◽  
Clearance Rate ◽  
Fluid Dynamic ◽  
Comsol Multiphysics ◽  
Cfd Model ◽  
Computational Tool ◽  
Glucose Clearance ◽  
User Friendly ◽  
The Impact ◽  
Solute Clearance

In order to reduce the hemodialysis cost and duration, an investigation of the effect of dialyzer design and process variables on the solute clearance rate is required. It is not easy to translate the in vivo transfer process with in vitro experiments, as it involves a high cost to produce various designs and membranes for the dialyzer. The primary objective of this study was the design and development of a computational tool for a dialyzer by using a computational fluid dynamic (CFD) model. Due to their complexity, only researchers with expertise in computational analysis can use dialyzer models. Therefore, COMSOL Inc. (Stockholm, Sweden) has made an application on membrane dialysis to study the impact of different design and process parameters on dialyzed liquid concentration. Still, membrane mathematical modeling is not considered in this application. This void hinders an investigation of the impact of membrane characteristics on the solute clearance rate. This study has developed a stand-alone computational tool in COMSOL Multiphysics 5.4 to fill this void. A review of the literature conducted shows that there are no suitable stand-alone computational tools for kidney dialysis. Very little work has been undertaken to validate the stand-alone computational tool. Medical staff in the hospitals require a computational tool that can be installed quickly and provide results with limited knowledge of dialysis. This work aims to construct a user-friendly computational tool to solve this problem. The development of a user-friendly stand-alone computational tool for the dialyzer is described thoroughly. This application simulates a mathematical model with the Finite Element Method using the COMSOL Multiphysics solver. The software tool is converted to a stand-alone version with the COMSOL compiler. The stand-alone computational tool provides the clearance rate of six different toxins and module packing density. Compared with the previous application, the stand-alone computational tool of membrane dialysis enables the user to investigate the impact of membrane characteristics and process parameters on the clearance rate of different solutes. The results are also inconsistent with the literature data, and the differences ranges are 0.09–6.35% and 0.22–2.63% for urea clearance rate and glucose clearance rate, respectively. Statistical analysis of the results is presented as mean with 95% confidence intervals (CIs) and p values 0.9472 and 0.833 of the urea and glucose clearance rates, respectively.

Study of Impact Velocity on Residual Stress and Surface Hardness of SKD11 in Shot Peening Process

2020 ◽  
Vol 304 ◽  
pp. 127-134
Author(s):  
Pudsadee Chupong ◽  
Karuna Tuchinda
Keyword(s):  
Residual Stress ◽  
Stress Distribution ◽  
Impact Velocity ◽  
Process Parameters ◽  
Material Properties ◽  
Shot Peening ◽  
Compressive Residual Stress ◽  
Surface Hardness ◽  
Impact Angle ◽  
Residual Stress Distribution

Shot peening process could create compressive residual stress and increase surface hardness and hence also used to improve material surface properties in case thermal effect is to be avoided. The shot peening process parameters such as pressure which result in different shot impact velocity could affect the compressive residual stress distribution which results in different post-process material properties. The ability to understand and predict the effect of process parameters on stress distribution could be very useful to control and obtain material properties as required. In this work, a shot peening process commercially available locally was investigated. The residual stress distribution after shot peening of SKD11 was studied using the finite element (FE) technique. A single shot impact was simulated. A maximum velocity with a miximum impact angle was assumed. The computational predictions showed higher compressive residual stress developed with increasing shot velocity as expected due to higher impact energy. However, experimental results suggested that the process arrangement and machine control highly affect the properties of the material after process. The compressive residual stress and surface hardness obtained experimentally was almost unchanged with an increase in pressure from 0.35MPa to 0.6MPa. It was found that, due to machine arrangement, an increase in impact velocity at higher pressure was relatively small and did not observed in all effected area due to fixed arrangement of nozzle and samples. Hence, research results suggested that a detail computational methodology including the effect of unevent impact velocity and impact angle should be employed to increase the predictive ability of the FE model. The current work could be extended to include such effects with no major difficulty to develop useful information for the design of shot peening process for any specific machine and arrangement.

Experimental investigations on the drilling parameters to minimize delamination and taperness of hybrid GFRP/Al2O3 composites by using ANOVA approach

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Gadhamsetty Guru Mahesh ◽  
Jayakrishna Kandasamy
Keyword(s):  
Optimum Condition ◽  
Process Parameters ◽  
Signal To Noise Ratio ◽  
Experimental Investigations ◽  
Content Type ◽  
Glass Fiber Reinforced Plastic ◽  
Glass Fiber Reinforced ◽  
Drilling Parameters ◽  
Drill Diameter ◽  
The Impact

Purpose Drilling holes in composite materials is a complex and challenging process because of their intrinsic anisotropic characteristics and unevenness compared to conventional metals. Hybridization of composites enhances the strength and hardness of the material but makes it more difficult to drill a hole in it. The purpose of this study is to optimize the drilling to minimize the delamination and taperness of hybrid glass fiber reinforced plastic (GFRP)/Al2O3 composites. Design/methodology/approach The present study investigates the impact of drilling parameters on delamination of the drilled hole and the taperness of the hole on hybrid GFRP/Al2O3. Optimum drilling conditions for minimizing delamination and taperness of the hole are determined to enhance the hole quality. Feed (f), speed (N) and drill diameter (D) are the parameters taken into consideration for drilling operation. By applying Taguchi’s signal-to-noise ratio analysis, process parameters have been optimized to reduce the delamination and taperness of holes on Hybrid GFRP/Al2O3 composites. The effect of process parameters was analyzed using the analysis of variance method. Findings The investigational results confirmed that the delamination is positively affected by speed, drill diameter and feed rate. Also, the taperness of the hole is positively affected by the drill diameter. Regression-based models were developed to predict the delamination and taperness of the hole matched with the experimental results, which are attained with an order of 95% and 97%. Originality/value Minimum delamination was found at the optimum condition of drill diameter 10 mm, feed at 0.225 mm/rev and the speed at 151 rpm and minimum taperness were found at the optimum condition of drill diameter 10 mm, feed at level 0.3 mm/rev and speed at 86 rpm for hybrid laminate composite (S-glass+ GFRP/Al2O3) were evaluated.

On Experimental Studies of Longitudinal and Flexural Wave Propagations: An Annotated Bibliography

1986 ◽  
Vol 39 (6) ◽  
pp. 853-865 ◽  
Author(s):  
M. M. Al-Mousawi
Keyword(s):  
Wave Propagation ◽  
Cross Section ◽  
Material Properties ◽  
Experimental Studies ◽  
Flexural Wave ◽  
Experimental Investigations ◽  
Velocity Impact ◽  
Flexural Wave Propagation ◽  
The Impact

Experimental investigations in the field of longitudinal wave propagation in beams are plentiful; however, experimental studies of flexural wave propagation problems are scarce and are restricted mainly to uniform and infinite structures where the effects of reflected waves are not generally included. This review is mostly restricted to low velocity impact and does not cover the so-called high velocity impact such as those of bullets and explosives. In addition to a brief survey of classical work related to impact, this article covers publications related to experimental studies of longitudinal and flexural elastic waves due to impact. This includes the longitudinal, central as well as eccentric impact and transverse impact of two bars and the impact achieved by sphere impinging on a beam. Many workers used experimental findings to study the adequacy of various theoretical solutions of the wave propagation problem such as those by Pochhammer and Chree, Euler–Bernoulli, and the Timoshenko beam theory. The revival of interest in the recent years is due to, among other things, the advancement of experimental equipment and measurement techniques for data acquisition of stress waves and associated signals. An important application of transient waves is their use for the determination of material properties under various loading conditions and strain rates that can be studied by the split Hopkinson pressure bar techniques. The problem of longitudinal and flexural waves in bars with discontinuities of cross section are covered, and some publications on fracture of materials due to bending waves are also included. Experimental investigations demonstrate the effect of abrupt change of cross section and/or material properties on reflected and transmitted waves where reflections are to be taken into consideration when estimating the level of stresses and strains in finite beam with discontinuities. In the field of flexural wave propagation, comparison of theoretical predictions with experimental results verified and validated the adequacy of the Timoshenko theory for the determination of bending strain in finite structures, a one-dimensional theory that takes into account the effect of shear deformation and rotatory inertia.

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