Simulating shot peen forming with eigenstrains

Faucheux, Pierre; Gosselin, Frédérick P.; Lévesque, Martin

doi:10.1016/j.jmatprotec.2017.11.036

Cited by 47 publications

(48 citation statements)

References 23 publications

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“…These include the known plastic anisotropy of rolled aluminum sheets used for most experiments (Prime, 2017), anisotropic initial residual stresses inherited from the manufacturing process of the sheets (e.g., quenching or rolling), and prestress, whether externally applied with a jig (Figure . 1b) or resulting from the progressive deformation of an unconstrained part (Figure . 1a). Although these phenomena were suspected to account for most of the discrepancies between experiments and numerical simulations of the process previously reported by our team in Gariépy et al (2013) and Faucheux et al (2018), this intuition could not be confirmed at the time due to a lack of experimental data.…”

Section: Introductionmentioning

confidence: 73%

Residual stress measurements of conventional and stress peen formed 2024-T3 aluminum sheets

Miao¹,

Faucheux²,

Lévesque³

et al. 2021

Preprint

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Aluminum skins on the lower wings of most commercial aircraft are shaped using shot peen forming. This process, which involves bombarding the skins with hard shot, uses nonuniform plastic flow to induce curvatures---in the same way that differential expansion makes metal bilayers bend when heated. Here, we investigate experimentally how constraining conditions affect the final shape of peen formed parts. We report peen forming experiments for 4.9 mm thick rectangular 2024-T3 aluminum sheets of different aspect ratios uniformly shot peened on one face with a low intensity saturation treatment. Some specimens were free to deform during peening while others were elastically prestressed in a four-point bending jig. For each aspect ratio and prestress condition, residual stresses were measured near the peened surface with the hole drilling method. Additional residual stress profiles were also obtained with the slitting method. The residual stress measurements show that the progressive deformation of unconstrained specimens had the same effect as an externally applied prestress. For the peening conditions investigated, this progressive deformation caused unconstrained strips to exhibit curvatures 33% larger than identical strips held flat during peening. Furthermore, we found that the relative importance of material anisotropy and geometric effects did determine the bending direction of unconstrained specimens.

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Section: Introductionmentioning

confidence: 73%

Residual stress measurements of conventional and stress peen formed 2024-T3 aluminum sheets

Miao¹,

Faucheux²,

Lévesque³

et al. 2021

Preprint

Self Cite

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“…In addition, uniform location of impacts combined with a square plate may lead to a non-spherical geometry owing to instability of geometry deformation. 18 With the methods proposed in this article, the resultant geometry of peened plate can be determined by FE simulation with nonlinear solutions.…”

Section: Resultsmentioning

confidence: 99%

“…Han et al 16 proposed that, in the first stage, the residual stress/strain profiles under the particular set of peening parameters were identified by simulating the peening process for a small-scale sample, and then in the second stage, the obtained stress/strain profiles were applied to the entire component to obtain the final shape. Gariépy et al 17 and Faucheux et al 18 obtained the residual stress profiles by simulating the practical peening processes, and then assigned the stress profiles to plates modeled with composite shell element. In the above equivalent numerical methods, the stress and strain distributions induced by shot impacts are averaged locally.…”

Section: Introductionmentioning

confidence: 99%

Prediction of peen forming stress and plate deformation with a combined method

Xiao

Sun

Tong

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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To simulate the deformations of the strip peen formed plate more realistic, and using low computational resources, a strategy combining analytical and finite element methods is proposed in this article. First, the internal stresses in the target induced by single shot impact are calculated with expanding cavity model. Second, the stress field of single shot impact is used to derive the stress field of multiple shot impacts by considering the overlaps of adjacent shot impacts. Third, the calculated stress field is introduced to the finite element model to obtain the resultant shape of the plate. The shot dimple distribution in reality is detected and fitted with normal distribution function. The random distribution of the positions of shot impacts is involved in the simulation to make the simulation more realistic. In the finite element model, the plate is modeled with shell element to reduce the demand of the computational resources. The simulated shapes of the plate under different peen forming parameters are compared with the scanned three-dimensional experimental shapes with the same forming parameters. The comparison shows that the simulated shapes are in good agreement with the experiments.

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“…Figure 20 shows photographs of the measured specimen. The specimen was deformed by shot peen forming process [20,21]. Shot peening was applied to the obverse side of the specimen with vertical scanning and the back side was applied with horizontal scanning to form a saddle shape.…”

Section: Application To Height Measurement Of a Curved Sheet Metalmentioning

confidence: 99%

Development of Quick Three-Dimensional Shape Measurement Projection Mapping System Using a Whole-Space Tabulation Method

et al. 2019

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A grating projection method is often used as a highly accurate 3D shape measurement method. A real-time 3D shape measurement system can also be applied to measure a wide and smooth curved surface, such as in sheet metal processing. In this case, operators take much effort to recognize the positions of some problem areas on an object from a measured result displayed on a monitor. This study develops a projection mapping system projecting an evaluation image, such as height, displacement, gradient, curvature factor, and area of defect, onto an object. These evaluation results are obtained from the measured 3D shape. The evaluation image should be deformed according to the 3D shape of the object because the camera and projector positions are different. Therefore, this study proposes a method to quickly produce a deformed evaluation image using a whole-space tabulation method. A coordinate transform table allowed the conversion of a camera pixel coordinate into a projector pixel coordinate by using reference planes to apply deformation to the evaluation image according to the measured 3D shape. The quick coordinate transformation from a camera pixel coordinate into a projector pixel coordinate was realized using the coordinate transform table. This is a key idea of this study. It was confirmed that the coordinate transformation from the camera pixel coordinate to the projector coordinate could be performed in 4.5 ms using the coordinate transform table. In addition, 3D shape measurement projection mapping was applied to a curved sheet metal with small deformation, and the deformation part was clearly shown by projecting the height distribution. The architecture and the experimental results are shown herein.

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Simulating shot peen forming with eigenstrains

Cited by 47 publications

References 23 publications

Residual stress measurements of conventional and stress peen formed 2024-T3 aluminum sheets

Residual stress measurements of conventional and stress peen formed 2024-T3 aluminum sheets

Prediction of peen forming stress and plate deformation with a combined method

Development of Quick Three-Dimensional Shape Measurement Projection Mapping System Using a Whole-Space Tabulation Method

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