Thin-walled aerostructural components frequently get distorted after the machining process.Reworking to correct distortions or eventually rejecting parts significantly increases the cost.This paper proposes a new approach to correct distortions in thin-walled components by strategically applying hammer peening on target surfaces of a machined component.Aluminium alloy 7475-T7351 was chosen for this research.The study was divided in two stages.First,the residual stresses(RS)induced by four different pneumatic hammer peening conditions(modifying the stepover distance and initial offset)were characterised in a test coupon,and one of the conditions was selected for the next stage.In the second stage,a FEM model was used to predict distortions caused by machining in a representative workpiece.Then,the RS induced by hammer peening were included in an FEM model to define two hammer peening strategies(varying the coverage area)to analyse the capability to reduce distortions.Two workpieces were machined and then treated with the simulated hammer peening strategies for experimental validation.Results in the test coupon showed that pneumatic hammer peening can generate high compressive RS(-50 to350 MPa)up to 800 lm depth,with their magnitude increasing with a reduced stepover distance.Application of hammer peening over 4% of the surface of the representative workpiece reduced the machininginduced distortions by 37%,and a coverage area of 100% led to and overcorrection by a factor of five.This confirms that hammer peening can be strategically applied(in target areas and changing the percentage of coverage)to correct low or severe distortions.
Aitor MADARIAGAMikel CUESTAGorka ORTIZ-DE-ZARATEEneko SAENZ-DE-ARGANDONADenis SORIANOMichael B.PRIMEPedro Jose ARRAZOLA
Shot peening is commonly employed for surface deformation strengthening of cylindrical surface part.Therefore,it is critical to understand the effects of shot peening on residual stress and surface topography.Compared to flat surface,cylindrical surface shot peening has two significant features:(i)the curvature of the cylindrical surface and the scattering of the shot stream cause dis-tributed impact velocities;(i)the rotation of the part results in a periodic variation of the impact velocity component.Therefore,it is a challenge to quickly and accurately predict the shot peening residual stress and surface topography of cylindrical surface.This paper developed a high-precision model which considers the more realistic shot peening process.Firstly,a kinematic analysis model was developed to simulate the relative movement of numerous shots and cylindrical surface.Then,the spatial distribution and time-varying impact information was calculated.Subsequently,the impact information was used for finite element modeling to predict residual stress and surface topography.The proposed kinematic analysis method was validated by comparison with the dis-crete element method.Meanwhile,9310 high strength steel rollers shot peening test verified the effectiveness of the model in predicting the residual stress and surface topography.In addition,the effects of air pressure and attack angle on the residual stress and surface topography were investigated.This work could provide a functional package for efficient prediction of the surface integrity and guide industrial application in cylindrical surface shot peening.
