Research Papers

Predicting the Peen Forming Effectiveness of Ti-6Al-4V Strips With Different Thicknesses Using Realistic Finite Element Simulations

[+] Author and Article Information
Fan Yang

School of Aerospace Engineering and
Applied Mechanics,
Tongji University,
Shanghai 200092, China
e-mail: fanyang@tongji.edu.cn

Yukui Gao

School of Aerospace Engineering and
Applied Mechanics,
Tongji University,
Shanghai 200092, China

1Corresponding author.

Contributed by the Materials Division of ASME for publication in the JOURNAL OF ENGINEERING MATERIALS AND TECHNOLOGY. Manuscript received June 8, 2015; final manuscript received October 14, 2015; published online November 4, 2015. Assoc. Editor: Vikas Tomar.

J. Eng. Mater. Technol 138(1), 011004 (Nov 04, 2015) (10 pages) Paper No: MATS-15-1130; doi: 10.1115/1.4031830 History: Received June 08, 2015; Revised October 14, 2015

This paper is intended to quantify the relationship between the peen forming effectiveness and various involved parameters through a realistic numerical study. For this purpose, a new finite element (FE) model is proposed with full geometry representation, random shots generation, and rate-dependent material law of kinematic strain-hardening. The mesh sensitivity and effects of boundary conditions are carefully examined. The FE model is validated by comparing the results with the experimental measurements. The proposed model is then used to investigate the effects of the peening intensity (represented as the shot velocity) and the strip thickness on the peen-formed deflection and the residual stress distribution for strips made of Ti-6Al-4V. Our results indicate the existence of a maximum convex deflection for different strip thicknesses. In addition, a reversed deflection (i.e., concaved curvature) is observed for severe peening conditions (i.e., thin strip under high peening intensity). Our simulations verify the previous proposition that a concaved curvature can be generated only when the whole cross section is plastically deformed.

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Fig. 1

Top view of the investigated strip constrained by the Almen fixture, with dimensions in mm. The dashed box indicates the simulated region in the FE model.

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Fig. 2

Three-dimensional configuration of the FE model with the coordinate axes

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Fig. 3

Flowchart of the whole numerical approach

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Fig. 4

Top view showing the boundary conditions and the impinging locations of the random shots that are arranged into multiple arrays, with the global view showing the first (dark) and second (light) arrays and the enlarged view showing the sequence of all the shots that fall within one periodic cell

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Fig. 5

Stress–depth profiles for different mesh refinements

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Fig. 6

Stress–depth profiles for different boundary conditions

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Fig. 7

Comparison of the simulated residual stress profile with that the experimental results in Ref. [10]

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Fig. 8

Contours of the stress σxx in x–y plane at three depths: (a) top, (b) the depth corresponding to the maximum stress, and (c) bottom

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Fig. 9

RMS deviation of the stress distribution at each depth

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Fig. 10

Strip deflection along the partition paths parallel to (a) the length and (b) the width, compared with those measured by the experiments in Ref. [33]

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Fig. 11

Averaged residual stress versus depth under the constraint of Almen fixture for the shot velocities of (a) 25 m/s, (b) 50 m/s, and (c) 75 m/s

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Fig. 12

Averaged residual stress versus depth after springback for the shot velocities of (a) 25 m/s, (b) 50 m/s, and (c) 75 m/s

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Fig. 13

Deflection development versus the number of the impinged shots for the shot velocities of (a) 25 m/s, (b) 50 m/s, and (c) 75 m/s

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Fig. 14

Final strip deflection versus thickness for different shot velocities

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Fig. 15

Plastic ratio versus thickness for different shot velocities




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