A Numerical Investigation of a Single-Shot in a DEM-FEM Approach to Shot Peening Simulation
Abstract
:1. Introduction
2. Theoretical Background
2.1. CoR Calculations for Single-Shot Impact in DEM
2.2. The Use of Contact Laws for a Single-Shot Impact in DEM
3. Numerical Formulation of the DEM-FEM Model for a Single-Shot Simulation
3.1. DE and FE Material Models Characterization
3.2. A Process Map for DEM-FEM Coupled Analysis
4. Single-shot Simulations
4.1. FEM Dynamic Simulation for CoR Calculation
4.2. Numerical Verification of FE Model
4.3. Discrete Element-Finite Element Coupled Simulation of Single-Shot
5. Numerical Results and Discussion
6. Conclusions
- The reactive contact forces generated in impact simulation by FEM is not responsible for the plastic strain in the workpiece, but for the rebound of the shot. Thus an attempt to generate the same contact force as in the FEM using the same CoR in the DEM for subsequent application in FEM cannot yield the required result.
- The kinematic CoR does not directly capture the energy lost by the shot, of which a greater portion (≥ 80 percent) is needed for induced CRS. Therefore, an energetic CoR should be utilized in establishing the needed force to be exported from DEM to FEM.
- The need to verify the accuracy of the model based on the established and related theoretical background to the concept investigated, vis-à-vis a single-shot analysis which serves as the foundation for a more complex multiple shots stream.
- The Hertz–Mindlin contact model cannot be used in DEM to generate the required contact force needed to produce the same plastic strain in FEM at a predetermined velocity. Thus, the Hysteretic–Spring contact model is a valuable tool for the purposed.
- The prospect of utilising DEM as a tool in simplifying the approach to shot peening simulation when coupled to FEM, thus avoiding the complexity and the current inability in generating a realistic shot stream by FEM.
- The simulation of a realistic SP process by a framework based on the current DEM-FEM approach is highly promising. Such a framework via the use of ANSYS workbench has the potential of incorporating the fatigue analysis of a load-bearing shot-peened component for benefits assessment. This will further enhance the SP process optimization, which is one of the aims of this research.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Property | Workpieces | Shots | ||
---|---|---|---|---|
Inco718 [40] | AISI 4340 [5] | Cast Steel [5] | CW-14 [29] | |
Elastic modulus (GPa) | 177.00 | 205.0 | 210 | 210 |
Density (kg/m3) | 8220.0 | 7800 | 7800 | 7800 |
Poisson’s ratio | 0.2730 | 0.29 | 0.28 | 0.30 |
Yield Strength (MPa) | 1036.0 | 1511 | Rigid | Rigid |
Tensile Strength (MPa) | 1240.0 | 1864 | n/a | n/a |
Material | A (MPa) | B (MPa) | C | n | m | TM (K) | |
---|---|---|---|---|---|---|---|
AISI 4340 [5] | 1498 | 943.8 | 0.0140 | 0.260 | 1.03 | 1793 | 1.0 |
Inconel718 [40] | 1108 | 699.0 | 0.0085 | 0.5189 | 1.0 | 1593 | 1.0 |
V1 (m/s) | V2 m/s | ere | Ere | FFEM (N) | FDEM (N) | Force Factor (FF) |
---|---|---|---|---|---|---|
25 | 23.60 | 0.9444 | 0.8919 | 47.75 | 30.836 | 1.548 |
50 | 46.115 | 0.9223 | 0.8506 | 106.476 | 70.05 | 1.520 |
62.5 | 56.95 | 0.9112 | 0.8303 | 146.726 | 90.62 | 1.619 |
75 | 67.425 | 0.899 | 0.8082 | 167 | 112.24 | 1.487 |
100 | 88.09 | 0.8809 | 0.7759 | 248.31 | 156.62 | 1.585 |
V1 (m/s) | V2 m/s | ere | Erp | FFEM (N) | FDEM (N) | Force Factor (FF) |
---|---|---|---|---|---|---|
25 | 11.373 | 0.4550 | 0.2064 | 31.843 | 21.33 | 1.492 |
50 | 18.777 | 0.3755 | 0.1410 | 62.039 | 44.93 | 1.381 |
62.5 | 22.103 | 0.3536 | 0.1250 | 74.739 | 51.82 | 1.292 |
75 | 24.750 | 0.3300 | 0.1089 | 88.720 | 70.62 | 1.256 |
100 | 30.311 | 0.3030 | 0.0918 | 114.303 | 95.92 | 1.192 |
V1 (m/s) | EL = 1 − Erp | Ep = Ere − Erp | FDEM (N) | Ave. FF | FFEM (N) | Ep/EL | |
---|---|---|---|---|---|---|---|
25 | 0.7936 | 0.7968 | 0.6855 | 28.636 | 1.52065 | 44.10 | 0.8638 |
50 | 0.8590 | 0.8289 | 0.7096 | 66.133 | 1..4500 | 95.89 | 0.8261 |
62.5 | 0.8750 | 0.8366 | 0.7053 | 86.26 | 1.4550 | 125.51 | 0.8060 |
75 | 0.8911 | 0.8443 | 0.6993 | 106.45 | 1.3715 | 145.99 | 0.7848 |
100 | 0.9082 | 0.8524 | 0.6841 | 151.00 | 1.3885 | 209.66 | 0.7533 |
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Edward, A.B.; Heyns, P.S.; Kok, S. A Numerical Investigation of a Single-Shot in a DEM-FEM Approach to Shot Peening Simulation. Metals 2019, 9, 1183. https://doi.org/10.3390/met9111183
Edward AB, Heyns PS, Kok S. A Numerical Investigation of a Single-Shot in a DEM-FEM Approach to Shot Peening Simulation. Metals. 2019; 9(11):1183. https://doi.org/10.3390/met9111183
Chicago/Turabian StyleEdward, Aghogho Bright, P. Stephan Heyns, and Schalk Kok. 2019. "A Numerical Investigation of a Single-Shot in a DEM-FEM Approach to Shot Peening Simulation" Metals 9, no. 11: 1183. https://doi.org/10.3390/met9111183