陈晟,丁腾飞,张朝阳,高建永,付婧颐,鲁世红.喷丸数值模拟中一种高效方法[J].表面技术,2023,52(8):458-465.
CHEN Sheng,DING Teng-fei,ZHANG Chao-yang,GAO Jian-yong,FU Jing-yi,LU Shi-hong.An Efficient Approach in Numerical Simulation of Shot Peening[J].Surface Technology,2023,52(8):458-465 |
| 喷丸数值模拟中一种高效方法 |
| An Efficient Approach in Numerical Simulation of Shot Peening |
| 投稿时间：2022-08-10 修订日期：2022-11-22 |
| DOI：10.16490/j.cnki.issn.1001-3660.2023.08.042 |
| 中文关键词: 喷丸 数值模拟 SAE 1070 弹丸间距 诱导应力 |
| 英文关键词:shot peening numerical simulation SAE 1070 shot distance induced stress |
| 基金项目: |
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| Author | Institution |
| CHEN Sheng | College of Mechanical & Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China |
| DING Teng-fei | College of Mechanical & Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China |
| ZHANG Chao-yang | Shandong Kaitai Shot Blasting Machinery Share Co., Ltd., Shandong Binzhou 256217, China |
| GAO Jian-yong | Shandong Kaitai Shot Blasting Machinery Share Co., Ltd., Shandong Binzhou 256217, China |
| FU Jing-yi | College of Mechanical & Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China |
| LU Shi-hong | College of Mechanical & Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China |
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| 中文摘要: |
| 目的 从减小分析步时间的角度出发，调整弹丸随机分布间距，研究提高模拟计算效率的方法。方法 以SAE1070弹簧钢为研究对象，在S230弹丸速度为40 m/s条件下，分析弹丸间垂直间距、水平间距和弹丸冲击方式对模拟结果的影响。结果 在不考虑弹丸间相互作用的前提下，有限元模拟中弹丸间可存在重叠，只要弹丸垂直间距大于0.07 mm，水平间距大于0.4 mm，弹丸随机生成模拟得到的诱导应力分布、塑性应变分布、粗糙度的结果在小偏差范围内收敛，与弹丸间无重叠的模拟结果相近。在满足弹丸间距阈值的前提下，采用同时冲击和顺序冲击方式得到的诱导应力分布在压应力部分区域存在一定偏差，但应力分布曲线整体较为接近，同时冲击的计算时间缩短了约90%。在此基础上，确定合适的弹丸分布，在不同弹丸直径、速度下进行阿尔门试片喷丸模拟，通过对比阿尔门强度值论证了模拟方法的有效性。结论 这种按层分布同时冲击，并在满足间距阈值的前提下尽可能减小间距的弹丸设置方法，保证了模拟精度，提高了计算效率，为数值模拟的应用提供了优化计算成本的新思路。 |
| 英文摘要: |
| Shot peening is a mechanical surface enhancement process widely used in the automotive and aerospace industry. The residual stress, as the main response parameter, plays an important role in improving the fatigue life of components. Compared with the costly and time-consuming experimental measurement, numerical simulation provides great convenience for the research of residual stress state, revealing mechanism and process optimization. Among them, the random multi-shot model can truly reflect the shot peening process, but it often faces the problem of high calculation cost, which limits the application of related technical methods. The shot peening model was established in Abaqus/Explicit in this paper. Therefore, from the perspective of increasing the spatial distribution density of shots to reduce the analysis step time, the distance and distribution mode of random shots were adjusted to study a simulation method that not only improved the calculation efficiency but also took into account the accuracy. Taking SAE1070 spring steel as the research object, the velocity of S230 shots was 40 m/s and the number of shots was 150 (not reaching full coverage). The shots were distributed in layers, and eight groups of different vertical distances between layers (0, 0.005, 0.01, 0.03, 0.05, 0.07, 0.3 and 0.6 mm) and six groups of different horizontal distances of shots in the same layer (>0.1, >0.2, >0.3, >0.4, >0.5 and >0.6 mm) were set respectively. Then, the effects of vertical distances and horizontal distances between shots on simulation results were analyzed. On this basis, the simultaneous impact and sequential impact of 150 and 300 shots were simulated, and the effect of shots impact mode on simulation results was analyzed. Then, according to the above research scheme, the distribution mode of shots was determined under different diameters and velocities, and a 1/4 Almen strip model based on real size was established. In the simulation, the number of shots was accumulated by data transfer between models, and an implicit solver was used to calculate the arc height of the spring-back strips under different numbers of shots, and the Almen intensity was obtained. Finally, the results achieved by the present approach were compared with those obtained in the literature. The results showed that, without considering the interaction between the shots, the shots could overlap in the finite element simulation, as long as the vertical distance was larger than 0.07 mm and the horizontal distance was larger than 0.4 mm, the results of induced stress distribution, plastic strain distribution and roughness obtained by simulation tended to be consistent, and under the premise of meeting the shots distance threshold, the results of induced stress distribution obtained by simultaneous impact and sequential impact were almost the same. Moreover, the calculation time was shortened by about 90%, which meant that it was more efficient to simulate the stress distribution of shot peening by simultaneous impact. Shot peening simulations of Almen strips demonstrated that Almen intensity obtained by the present approach matched much better with the literature. In addition, the results showed that the greater the kinetic energy of the same kind of shots, the less number of shots needed to reach the saturation point, and high coverage had no significant effect on the arc height. This approach of setting shots with simultaneous impact by layer distribution and reducing the distance between shots on the premise of satisfying the distance threshold improves the calculation efficiency, ensures the simulation accuracy of the stress state, is suitable for the simulation of shot peening and deformation of the slightly larger target, and provides a new idea to optimize the calculation cost for the application of numerical simulation. |
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