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

机译：用于喷丸处理过程的模拟和定性评估的基于FEM的2D模型

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摘要

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.
机译：射击喷丸是最受欢迎的表面处理过程之一，主要用于大规模工程部件，以提高疲劳性能。由于过程参数的随机性质和相互相互作用和组件表面造成的部分矛盾效果（剩余应力，工作 - 硬化和粗糙度的增加），需要有能力和用户友好的模拟模型支持负责工程师开发最佳射击喷丸过程。本文包含一种基于用户友好的有限元方法的2D模型，涵盖了所有主要的过程参数。它的新颖性和科学突破在其能够考虑各种尺寸分布和弹性塑料材料的镜头的能力。从而，该模型能够深入了解每个单独的过程参数及其交互的影响。尽管其2D性质产生了一定的限制，但可以准确地申请模型的定性或比较研究和流程评估，以便为进一步的实验研究选择最有希望的一个。考虑实际射击尺寸分布，该模型应用于用于汽车叶片弹簧的高强度钢级。结果表明，射击速度和冲击角的增加增加了残余应力的程度，而且增加了表面粗糙度。已经证明了对镜头的弹性材料性能的使用是至关重要的，以获得关于组成部分行为的物理合理的结果。

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