ISSN (print) 1995-2732
ISSN (online) 2412-9003

 

download PDF

DOI: 10.18503/1995-2732-2022-20-4-120-128

Abstract

Problem Statement (Relevance). One of the most complicated elements in the plane design is large-size outer mold line panels and shell. Manufacturing complexity is attributed to a peculiar spatial outline, namely a combination of zones of fluctuating double curvature and large size (length of such parts may be 30 m) and low stiffness. An efficient approach to manufacturing a double curvature shape is surface plastic deformation methods, namely shot peening and local treatment (flattening-out and fitting of edges). Most methods used to determine mode parameters of the processes are based on experimental studies on curvature and elongation of samples during treatment, and elasticity theory in studies on residual stresses. Objectives. The research is aimed at improving the methods used to calculate mode parameters of metal forming by surface plastic deformation. Methods Applied. finite element modeling of the surface plastic deformation process using shot peening as an example. Originality. It lies in using a concept of initial stresses, being a source of bending strain and extensional strain, to describe a shot peening processes. Results. The authors developed methods for determining the distributions of the initial stress-strain state of the surface layer of element sections of parts, and for integrating the initial stress-strain state into the surface layer of full-scale parts in order to obtain the predicted curvature of the parts in the required direction. The simulation results were compared with the available results of experimental studies on the processing of plate samples by the shot peening method. Practical Relevance. An approach of initial stresses applied to describe the shot peening process contributes to calculating mode parameters of the processes, showing no need for a large number of experimental studies. Computer simulation methods were applied to settle a range of issues aimed at increasing efficiency and quality of manufacturing outer mold line parts of a complicated shape by finding patterns of forming the stress-strain state, when processing parts.

Keywords

surface plastic deformation, metal forming, residual stresses, initial stresses, stress-strain state

For citation

Pashkov A.E., Pashkov A.A., Samoylenko O.V. Development of Initial Stresses During Shot Peening. Vestnik Magnitogorskogo Gosudarstvennogo Tekhnicheskogo Universiteta im. G.I. Nosova [Vestnik of Nosov Magnitogorsk State Technical University]. 2022, vol. 20, no. 4, pp. 120-128. https://doi.org/10.18503/1995-2732-2022-20-4-120-128

Andrey E. Pashkov – DrSc (Eng.), Professor of the Department of Machine-Building Production Technology and Equipment, Irkutsk National Research Technical University, Irkutsk, Russia. Email: This email address is being protected from spambots. You need JavaScript enabled to view it..

Aleksandr A. Pashkov – PhD (Eng.), Associate Professor of the Department of Machine-Building Production Technology and Equipment, Irkutsk National Research Technical University, Irkutsk, Russia. Email: This email address is being protected from spambots. You need JavaScript enabled to view it..

Oleg V. Samoylenko – Researcher of the Department of Machine-Building Production Technology and Equipment, Irkutsk National Research Technical University, Irkutsk, Russia. Email: This email address is being protected from spambots. You need JavaScript enabled to view it..

1. Increasing the shape accuracy of the hardened parts of the frame by technological methods. Materials Sci-ence and Engineering: IOP Conference Series, 2019, 632. DOI: 10.1088/1757-899X/632/1/012100

2. Pashkov A.E., Malashchenko A.Y., Pashkov A.A. On creating digital technologies for the production of large aircraft frame and skin parts. Russian Metallurgy (Metally), 2021, 2021, 13, 1777-1785. DOI: 10.1134/S003602952113022X

3. Pashkov A.E., Malashchenko A.Y., Pashkov A.A., Bogdanov K.V., Kryuchkin A.V. Devel-opment of digital manufacturing technologies for frame and casing parts. Materials Science and Engineering: IOP Conference Series, 2019, 632. DOI: 10.1088/1757-899X/632/1/012104

4. Pashkov A.E., Malashchenko A.Y., Pashkov A.A., Duk A.A. The upgrade of peen forming equipment for long-sized aircraft parts. Materi-als Science and Engineering: IOP Conference Series, 2021, 1061. DOI: 10.1088/1757-899X/1061/1/012029

5. Koltsov V.P., Vinh Le Tri, Starodubtseva D.A. Determination of the allowance for grinding with flap wheels after shot peen forming. Materials Science and Engineering: IOP Conference Series, 2019, 632. https://doi.org/10.1088/1757-899X/632/1/012096

6. Belyakov V.I. Shtampovka na spetsialnom obo-rudovanii [Stamping on special equipment]. Moscow: Mashgiz, 1983, 79 р. (In Russ.)

7. Okhrimenko Ya.M. Osnovy tekhnologii goryachey shtampovki [Basics of die forging technology]. Moscow: Mashgiz, 1975, 285 р. (In Russ.)

8. Makaruk A.A., Minaev N.V. Technology of shaping and straightening of low-rigidity parts by local plastic deformation methods. Materialy Vserossiiskogo nauchno-prakticheskogo seminara s mezhdunarodnym uchastiem [Proceedings of the All-Russian Scientific and Practical Workshop with an international participation]. Irkutsk: Irkutsk State Technical University, 2011, pp. 117-121. (In Russ.)

9. Makaruk A.A., Minaev N.V. Technology of shaping and straightening of low-rigidity parts by means of roller burnishing. Izvestiya Samar-skogo nauchnogo tsentra Rossiiskoi akademii nauk [Izvestia of Samara Scientific Center of the Russian Academy of Sciences], 2013, vol. 15, no. 6, pp. 404-408. (In Russ.)

10. Kravchenko G.N. Rationale for efficiency of re-storing the fatigue life of surface hardened air-craft parts by repeated shot peening. Vestnik mashinostroeniya [Bulletin of Mechanical Engi-neering], 2019, no. 12, pp. 69-75. (In Russ.)

11. Birger I.A. Ostatochnye napryazheniya [Residu-al stresses]. Moscow: Mashgiz, 1963, 232 p. (In Russ.)

12. Isaev A.I., Ovseenko A.N. Selecting optimal thickness of samples for determining residual stresses in the surface layer. Vestnik mashi-nostroeniya [Bulletin of Mechanical Engineer-ing], 1967, no. 8, pp. 74-76. (In Russ.)

13. Pashkov A.E., Chapyshev A.P., Pashkov A.A., Vikulova S.V., Andryashina Yu.S. Determination of internal force factors of the shot peening process. Vestnik Irkutskogo gosudarstvennogo tekhnicheskogo universiteta [Proceedings of Irkutsk State Technical University], 2017, vol. 21, no. 12, pp. 43-55. DOI: 10.21285/1814-3520-2017-12-43-55

14. Ramati S., Levasseur G., Kennerknecht S. Single piece wing skin utilization via advanced peen forming technology. The 7th Int. Conf. on Shot Peening, Warsaw, Poland, 28-30 Sept. 2000, p. 1-18, pp. 1528-1535.

15. Diyak A.Yu. Shot coverage degree estimation by a computer-aided method. Vestnik Irkutskogo gosudarstvennogo tekhnicheskogo universiteta [Proceedings of Irkutsk State Technical Univer-sity], 2015, no. 12, pp. 19-25. (In Russ.)

16. Koltsov V.P., Vinh Le Tri, Starodubtseva D.A. Surface roughness formation during shot peen forming. Materials Science and Engineering: IOP Conference Series., 2018, 327(4). DOI: 10.1088/1757-899X/327/4/042125

17. Makaruk A.A., Minaev N.V. Improving effi-ciency of low-rigid ribbed parts forming and straightening by roller burnishing. Vestnik Ir-kutskogo gosudarstvennogo tekhnicheskogo universiteta [Proceedings of Irkutsk State Technical University], 2015, no. 12 (107), pp. 63-70. (In Russ.)

18. Murugaratnam K., Utili S., Petrinic N. A com-bined DEM–FEM numerical method for shot peening parameter optimization. Advances in Engineering Software, 2015, 79, 13-26. https://doi.org/10.1016/j.advengsoft. 2014.09.001

19. Miao H.Y., Larose S., Perron C., Evesque M. On the potential applications of a 3D random finite element model for the simulation of shot peening. Advances in Engineering Software, 2009, 40(10), 1023-1038. https://doi.org/10.1016/j.advengsoft.2009.03.013

20. Chen Zhuo, Yang Fan, Meguid S.A. Realistic fi-nite element simulations of arc-height develop-ment in shot-peened Almen strips. Journal of Engineering Materials and Technology, 2014, 136 (4). https://doi.org/ 10.1115/1.4028006

21. Tu Fubin, Delbergue D., Miao Hongyan, Klotz T., Brochu M., Bocher P. et al. A sequential DEM-FEM coupling method for shot peening simulation. Surface and Coatings Technology, 2017, 319, 200-212. https://doi.org/10.1016/j.surfcoat.2017.03. 035