Session: Research Posters

Paper Number: 119855

119855 - A Novel Simulation Framework to Model Shot Peening Using a Multiscale Approach 

Shot peening is a widely employed surface treatment technique that enhances the mechanical properties and fatigue life of components in various industries, including automotive, aerospace, and manufacturing. However, conventional experimental investigations to understand the effects of shot peening are often costly, time-consuming, and limited in scope. To address these challenges, a novel simulation framework is proposed in this study, which leverages the combined capabilities of a finite element method (FEM) solver and a discrete element method (DEM) solver.

A robust finite element analysis tool, serves as the foundation of the simulation framework, enabling the accurate modeling of the dynamic material response during the shot peening process. It accurately captures the intricate interactions between shot particles and the target material, incorporating factors such as interaction forces, material deformation, and the distribution of residual stresses. By integrating material properties, process parameters, and shot particle characteristics, the finite element solver provides valuable insights into the changes induced by shot peening in the mechanical behavior of the targeted component. Due to computational restrictions, conventional finite element solvers cannot be used to simulate the shot peeing event for a copious number of shot particles. Hence, the finite element solver is chosen to solve the shot peening process in a mesoscopic scale.

The simulation framework leverages its integration with a Discrete Element Method (DEM) solver, which enhances its capabilities by utilizing a rich data set acquired from mesoscopic simulations conducted through the traditional Finite Element Method (FEM) solver. This combination ensures computational efficiency and accuracy in the analysis of multiple shot particles at a macroscopic scale, encompassing diverse target geometries, shot positions and velocities. This integration between the DEM solver and the mesoscopic simulations obtained from the FEM solver optimizes computational resources while providing reliable and detailed insights into trajectories, impact velocities, angles, and energies of the particles, thus facilitating an advanced analysis of the shot peening process.

Within the proposed simulation framework, virtual investigations into the effects of shot peening with an abundant number of shot particles becomes possible. Through iterative simulations and analysis of the obtained results, engineers and researchers can explore various scenarios and design parameters to optimize the shot peening process. Additionally, the framework enables the examination of different target geometries for area of coverage, and residual stress distribution through depth, offering valuable insights into the applicability of shot peening across diverse industries.

Compared to traditional experimental approaches, the proposed simulation framework provides several distinct advantages. First, it significantly reduces costs and time associated with physical experiments. Instead of conducting expensive and time-consuming tests, engineers can virtually explore the effects of shot peening through computer simulations. This enhanced efficiency facilitates quicker design iterations and process optimization. Second, the simulation framework offers increased flexibility by allowing the adjustment of various input parameters and conditions. This flexibility enables engineers to study the influence of different process variables on the outcomes of shot peening, providing valuable guidance for process optimization. Third, the simulation framework offers a level of detail that is challenging to achieve experimentally. It enables the examination of intricate details of the shot peening process, such as localized stress concentrations, deformation patterns, and particle interactions, which are difficult to capture using traditional experimental techniques.

In conclusion, the novel simulation framework utilizing a FEM solver and DEM solver, presents a powerful and efficient approach to virtually investigate the effects of shot peening. By simulating the peening process and analyzing the obtained results, valuable insights can be gained into the changes in mechanical behavior induced by shot peening. The framework offers cost and time savings, enhanced flexibility, and the ability to study intricate details of the process.

Presenting Author: Satish Kumar Meenakshisundaram Ansys Inc.,

Presenting Author Biography: Satish Kumar M is an experienced Mechanical Engineer specializing in Structural Mechanics, FSI, and Simulation Process Automation. He is a seasoned expert in utilizing advanced simulation tools to research and develop complex simulation methods. His expertise spans across various industry verticals, enabling him to tackle convoluted problems. Satish holds a graduate degree in engineering and works for Ansys Inc. as an Application Engineer.

Authors:

Satish Kumar Meenakshisundaram Ansys Inc.,
Sunil Acharya Ansys
Ahmad Haghnegahdar Ansys