Effect of shot peening on rolling contact fatigue and lubricant film thickness within mixed lubricated non-conformal rolling/sliding contacts

The effect of shot peening on rolling contact fatigue (RCF) and lubricant film thickness within non-conformal rolling/sliding contacts operated under mixed lubrication conditions was observed in this study. Rolling contact fatigue tests and film thickness measurements were carried out using specimens with modified surface topography by shot peening process using glass beads having diameter between 0.07 and 0.11 mm. It has been shown that the effect of shot peening on RCF has no positive effect even if shot peened surface of the roller exhibited somewhat higher hardness in contrast to the grounded surface. The reduction of RCF may be caused due to asperities interactions because after shot peening the surface roughness of the roller was increased. Film thickness measurements confirmed that the contact is realized actually only between asperity peaks of shot peened ball and smooth disc.Conversely, no negative effect on RCF was observed when the shot peened surface of the roller was polished. The polish of asperity peaks causes the creation of lands and micro-cavities, which may be employed as lubricant micro-reservoirs. From film thickness measurements it has been observed that lubricant emitted by shallow micro-cavities can provide the local increase in lubrication film thickness, which thereby reduces asperities interactions. Similar results were obtained for start-up conditions where the squeeze lubricant enlarges film thickness and reduces surface interactions.From the obtained results, it can be suggested that properly designed surface topography modification could help to increase the efficiency of lubrication films leading to the enhancement of contact fatigue life of non-conformal mixed lubricated rolling/sliding contacts.     

激光冲击强化与喷丸提高不锈钢疲劳性能对比研究

对不锈钢材料1Cr11Ni2W2MoV进行了激光冲击强化和喷丸强化后表面粗糙度和残余应力测试分析,与喷丸相比,激光冲击强化对试件表面形貌和表面粗糙度的影响更小,产生的残余压应力更大。对光滑试件和2种强化后试件的振动疲劳对比试验表明,激光冲击强化能显著提高不锈钢材料振动疲劳寿命,是喷丸的2倍以上。     

喷丸强化在新能源汽车轴齿上的应用

针对某新能源输入轴上仿真安全因子偏低的齿轮进行喷丸强化,结合其喷丸强化重点区域进行了有效的工装和喷丸饱和曲线工艺设计。同时,对喷丸后的齿面粗糙度以及规定位置进行了残余应力测试。喷丸后的输入轴应力合格及满足整车耐久测试要求,确认合理的喷丸能有效改善轴齿的应力状态,提高其弯曲和接触安全系数。     

Influence of coating thickness on rolling contact fatigue of alumina ceramics thermally sprayed on steel roller

The influence of the sprayed layer thickness on rolling contact fatigue of a thermally sprayed alumina ceramics with a nominal composition of Al₂O₃–2.3 mass% TiO₂ was investigated using a two-roller test machine under pure rolling contact condition with oil lubricant. The influence of undercoating of sprayed nickel-based alloy on rolling contact fatigue was also investigated. Thicknesses of the ceramics-sprayed layer of tested rollers were 0.2, 0.5 and 1.0 mm. The failure mode of sprayed rollers was spalling caused by subsurface cracking. In the case of sprayed rollers without undercoating, rolling contact fatigue strength of rollers with 0.2 mm thickness sprayed layer was the smallest. Rolling contact fatigue strength of sprayed roller with 0.2 mm thickness sprayed layer was improved by undercoating. In case the failure depth was small as compared with the thickness of sprayed layer, effect of undercoating on the rolling contact fatigue strength was little. The depths where the maximum values of subsurface shear stresses occurred, almost corresponded to the observed depth of spalling cracks.     

喷丸强化残余应力对疲劳性能和变形控制影响研究进展

作为机械表面强化技术之一,喷丸强化使工件表层发生形变硬化,引入较高的残余压应力,减少了疲劳应力作用下微裂纹的萌生并抑制其扩展,从而显著提高零件的抗疲劳断裂和抗应力腐蚀开裂的能力。基于喷丸残余应力解析计算模型,从余弦函数模型、接触应力模型和球腔膨胀模型三个方面介绍喷丸强化残余应力的产生,进而对喷丸残余应力的仿真预测及影响规律进行论述。为了提高试件疲劳强度而引入的残余压应力会带来影响形位精度的变形,基于此阐述了喷丸残余应力对疲劳性能的影响及其在疲劳过程中的演化,同时论述了喷丸残余应力变形预测及控制的研究现状,最后对喷丸残余应力未来的研究内容与发展方向进行展望。     

Numerical Calculation and Experimental Research on Residual Stresses in Precipitation-hardening Layer of NAK80 Steel for Shot Peening

Shot peening can improve fatigue strength of materials by creating compressive residual stress field in their surface layers,and offers a protection against crack initiation and propagation,corrosion,etc.And fatigue fracture and stress corrosion cracking of NAK80 steel parts are improved effectively.Currently there lacks in-depth research in which the beneficial effect of the residual stress may be offset by the surface damage associated with shot peening,especially in terms of the research on the effective control of shot peening intensity.In order to obtain the surface residual stress field of NAK80 steel after shot peening,the samples are shot peened by pneumatic shot peening machine with different rules.The residual stress in the precipitation-hardening layer of NAK80 steel is measured before and after a shot peening treatment by X-ray diffraction method.In order to obtain true residual stress field,integral compensation method is used to correct results.By setting up analytical model of the residual stress in the process of shot peening,the surface residual stress is calculated after shot peening,and mentioning the reason of errors occurred between calculated and experimental residual stresses,which is mainly caused by the measurement error of the shoot arc height.At the same time,micro hardness,microstructure and roughness in the precipitation-hardening layer of NAK80 steel before and after shot peening were measured and surveyed in order to obtain the relation between shot peening strength and surface quality in the precipitation-hardening layer.The results show that the surface quality of NAK80 steel is significantly improved by shot peening process.The over peening effect is produced when the shot peening intensity is too high,it is disadvantageous to improve sample’s surface integrity,and leading to reduce the fatigue life.When arc high value of optimal shot peening is 0.40 mm,the surface quality is the best,and the depth of residual stress in the precipitation-hardening layer reaches to about 450 μm.Numerical calculation is very useful to define the process parameters when a specific residual stress profile is intended,either to quantify the benefits on a specific property like fatigue life or to help on modeling a forming process like shot peen forming.In particular,the proposed parameter optimization in the progress of shot peening and effective control of the surface texture provide new rules for the quantitative evaluations of shot peening surface modification of NAK80 steel.     

Impact of surface hardening treatment generated by shot peening on the fatigue life of brass alloy

Brass alloy is widely used because of some attractive properties such as high electrical and thermal conductivity. But its fatigue performance after surface treatment is not very well explored in literature. Thus, in the present work, particular emphasis was given to the influence of surface treatment by shot peening on the fatigue life of brass alloy, throughout surface roughness and microstructural evolution. Fatigue tests were performed on unpeened, peened and peened then polished specimens. Various times of surface hardening treatment as 30, 60 and 120 min were considered. Experimental results reveal that the fatigue life of peened brass alloy decrease for all studied hardening treatment conditions. Surface roughness and microstructural properties showed large sensitivity to the shot peening process of brass alloy.     

喷丸与激光喷丸强化高强度钢对比试验

为了考察和对比喷丸(SP)和激光喷丸(LSP)2种表面强化技术对金属零件的强化效果,以30CrMnSiNi2A钢为试样,进行喷丸和激光喷丸强化处理试验。试验结果显示,2种强化试样的残余压应力和硬度都有较大的提高。分别测定了喷丸强化和激光喷丸强化试样在同一应力水平下的疲劳寿命,并运用扫描电镜分析了两者的疲劳断口。试验结果表明,激光喷丸强化试样中值疲劳寿命是喷丸强化试样的1.11~2.75倍,激光喷丸强化比喷丸强化在提高金属零件表面性能方面的效果更佳。     

喷丸强化因素对钛合金固体粒子冲蚀抗力的影响

探讨了喷丸强化(SP)因素(残余压应力引入、表面粗糙度增大和表面加工硬化等)对Ti6Al4V钛合金固体粒子冲蚀(SPE)行为的影响和作用机制,为充分发挥SP改进航空发动机零部件服役性能的潜力提供依据。结果表明:Ti6Al4V合金表面直接喷丸处理,其SPE抗力无明显改变;SP处理后进行表面抛光,Ti6Al4V合金SPE抗力明显增加。SP造成的表面粗糙度增大导致了钛合金在大小冲击攻角下的SPE抗力的下降;SP引入的表面残余压应力对提高钛合金在90°大攻角下的SPE抗力起了重要作用,原因是SP残余压应力增加了裂纹闭合力和抑制了疲劳裂纹早期扩展;SP引起的表面加工硬化作用对提高钛合金在30°小攻角下的SPE抗力有重要贡献,这归于加工硬化提高了材料表面在小攻角下的微犁削抗力。     

Failure Mechanisms in High-Density Polyethylene Rollers

This paper describes failure processes in plastic rollers that undergo rolling contact, and the effect of initial surface roughness upon wear and rolling fatigue. Experiments were performed with mating cylindrical rollers of high-density polyethylene (PE rollers) and chrome-plated cylindrical driving rollers. Surface roughness of the PE roller is affected by three successive transition processes. In the first period, the amount of wear can hardly be measured, although a reduction of surface roughness is noted. During the second period, wear occurs in proportion to the initial surface roughness. In the third period, wear becomes independent of the initial surface roughness, and increases in a manner exponential to load. At the end of this period, small cracks appear randomly, and grow into pits. Roller fatigue Life, defined by the time when cracks appear, is shown by an S-N curve. It is found that fatigue limiting stress, represented by Hertz stresses, is about 10⁷pa.     

Effect of Tangential Traction and Roughness on Crack Initiation/Propagation During Rolling Contact

Rolling-fatigue tests of 0.45 percent carbon steel rollers were carried out using a four-roller-type rolling-contact fatigue tester. Tangential traction and surface roughness of the harder mating rollers were varied and their effect was studied. The results of the study indicate that the fatigue life decreases when traction is applied in the same direction as that of rolling. When the direction of traction is reversed, the life increases over that obtained with zero traction. The roughness of harder mating rollers also has a marked influences on life. The smoother the mating roller, the longer the life. Microscopic observation of specimens revealed that the initiation of cracks during the early stages of life is more strongly influenced by the surface roughness, while the propagation of these cracks in the latter stages is affected mainly by the tangential traction.     

Influence of process parameters on surface roughness of aluminum parts produced by DMLS

Direct metal laser sintering (DMLS) is an additive manufacturing technique for the fabrication of near net-shaped parts directly from computer-aided design data by melting together different layers with the help of a laser source. This paper presents an investigation of the surface roughness of aluminum samples produced by DMLS. A model based on an L₁₈ orthogonal array of Taguchi design was created to perform experimental planning. Some input parameters, namely laser power, scan speed, and hatching distance were selected for the investigation. The upper surfaces of the samples were analyzed before and after shot peening. The morphology was analyzed by means of field emission scanning electron microscope. Scan speed was found to have the greatest influence on the surface roughness. Further, shot peening can effectively reduce the surface roughness.     

喷砂工艺对双金属带锯条锯切性能和疲劳寿命的影响

用快速高压喷砂和慢速低压喷砂两种喷砂工艺对双金属带锯条进行处理,通过锯切GCr15和空转疲劳测试,分别对比两种工艺处理后带锯条的锯切寿命和疲劳寿命。通过影像测量仪和扫描电镜观察带锯条锯刃和锯条体表面形貌,通过X射线衍射检测带锯条锯条体表面的残余应力。结果表明:与快速高压喷砂相比,慢速低压喷砂能够优化锯齿齿尖形貌,减少锯切过程中的崩刃,从而提高带锯条的锯切性能;同时还能增加锯条体表面残余压应力,并使表面形貌均匀,从而提高带锯条的疲劳寿命。     

The effect of changing the rolling direction on the rolling contact fatigue lives of annealed and case-hardened steel rollers

The effects of changing the rolling direction and of repeated loading on the rolling contact fatigue lives of annealed 0.45% carbon steel rollers and case-hardened nickel-chromium steel rollers under conditions of sliding rolling contact were studied. The influence of plastic flow in the subsurface layer on the rolling fatigue life was examined. The increase in the rolling fatigue life of an annealed steel roller due to a change in the rolling direction was significant, especially when the rolling direction was changed just before the formation of macroscopic surface cracks and pits. The effect with case-hardened steel rollers was negligible. The varying effects of changing the rolling direction on the rolling fatigue life were due to differences in work-hardening and the extent of plastic flow in the rollers.     

Process characterization of vibrostrengthening and application to fatigue enhancement of aluminum aerospace components��part II: Process visualization and modeling

In a companion paper [1], vibrostrengthening was introduced as a fatigue life enhancement process that can be used as an alternative to shot peening. Vibrostrengthening is a modification of a typical vibratory finishing process; it maintains the workpiece fixed inside a vibrating tub filled with a granular (typically ceramic or metal) medium. The resulting interaction between granular medium and workpiece produces improved fatigue resistance. Experimental results indicate that the vibrostrengthening process produced significant improvement in fatigue resistance on baseline (as machined) samples and performance as well, if not better than shot peening. The enhanced fatigue life produced by vibrostrengthening is thought to be the result of the combined effects of the improved surface finish and the compressive residual stress field that the process produces on the workpiece??s surface. Curiously, compared to shot-peening, the velocities (and hence kinetic energy) of an individual particle impinging on the workpiece??s surface is much smaller. Yet, the levels of subsurface stresses are comparable to those seen in shot-peened specimens. This paper makes two contributions to the understanding of the vibrostrengthening process. Through an experimental study using high-speed video recordings of the granular medium and motion analysis to correlate the instantaneous dynamics of particles impinging on the workpiece, it provides evidence that a single impingement event transfers the momentum of a number of particles from the granular medium to the workpiece, thus providing a plausible explanation for the plastic deformation and the resulting compressive stress field observed after the process. It also gives estimates of the effective number of particles participating in such an event. The study of the motion of the particles relative to the workpiece also explains variations in the effectiveness of the process in producing a fatigue strength enhancement with changes in location of the workpiece within the media tub. The second contribution the paper makes is in the development of a model to predict the expected fatigue life of a workpiece, given the surface finish and the residual stress levels introduced by the vibrostrengthening process. In the companion paper [1], we concluded that the fatigue life enhancement is the result of vibrostrengthening improving the surface finish and introducing a compressive residual stress field near the surface. Therefore, we introduce a model that, if given measured values of the surface roughness and the residual stress field, can predict fatigue crack propagation and hence the life of the specimen.     

喷丸对TC4钛合金材料叶片的影响研究

文章主要通过试验的方式,研究喷丸对钛合金材料(Ti-6Al-4V)长叶片的疲劳寿命、表面粗糙度、表面完整性、渗入Fe元素含量等的影响,为确定合理的钛合金材料长叶片喷丸方式提供一定的帮助。     

Effect of shot peening coverage on fatigue limit in round bar of annealed medium carbon steel

Shot peening is an effective and economical technique for improving the fatigue strength of metallic components by inducing compressive residual stress and hardening the layer near the surface. The effect is generally evaluated by main two parameters: coverage and peening intensity. However, the valuable coverage for improving the fatigue strength depends on the shape of the target material. In this study, the effect of coverage on fatigue limit in round bar of annealed medium carbon steel was experimentally studied. The fatigue limits for shot peened round bar specimens with 140–2300% coverage increased 14–25% by comparing those for non-peened round bar specimens. The valuable range of coverage was 280–60% in the used material and shot peening condition for improving the fatigue limit in short time. The result indicates that the valuable coverage of the round bar material is higher than full coverage to improve the fatigue limit of the material due to the effect of incident angle on round bar, even though the degree depends on the materials and shot peening conditions.     

Effect of shot peening parameters on microhardness of AISI 1045 and 316L material: an analysis using design of experiment

Shot peening is widely used to improve the fatigue properties of components and structures. Residual stresses, surface roughness, and work hardening are the main beneficial effects induced in the surface layer from shot peening, which depend on the correct choice of the peening parameters. In this investigation, experiments were designed using the full factorial design of experiment (DOE) technique and an air blast type of shot peening machine. Effects of process parameters such as pressure, shot size, stand-off distance, and exposure time on surface microhardness for AISI 1045 and 316L materials were investigated. An ANOVA was carried out to identify the significant peening parameters. In the case of 316L material, the maximum surface hardness was found to be in the range of 450–824 Hv, whereas it was found to be in the range of 314–360 Hv for AISI 1045. A critical assessment was made so as to understand the variation of microhardness in the direction of peening. Empirical equations between the peening parameters and the surface microhardness for both materials were developed, which are useful in predicting the surface microhardness. It is believed that this technique could prove beneficial in industries for reduction of performance variation and cost and to increase productivity.     

A non-local fatigue approach to quantify Ti-10V-2Fe-3Al fretting cracking process: Application to grinding and shot peening

This paper presents an experimental study on the tribological behaviour and cracking response of a Ti-10V-2Fe-3Al titanium alloy under fretting loading with a cylinder on plane configuration. Three types of surfaces were investigated: a polished one considered as the reference, a ground one and a shot peened surface. Surfaces were compared with respect to residual stress, hardness and roughness. The first step of this study was to determine sliding conditions and coefficient of friction of the three contact types. Next, fretting tests under stabilized partial slip regime were carried out to investigate crack nucleation and propagation. Results show that whatever surface roughness or residual stress in the material, tribological behaviour is the same. These latter confirm that sliding condition and coefficient of friction in partial slip regime is due to material effect and not to roughness or surface hardness. Then, residual stress induced by grinding or shot peening have no influence on the crack nucleation threshold under fretting solicitation because crack nucleation is only induced by a sufficient tangential loading. The crack nucleation threshold is formalized by applying the Crossland criterion taking into account the stress gradient and the ensuing “size effect”. As expected, cracks propagation is influenced by residual stress under the surface. Compared to the reference case, for a same loading parameters set, residual stress induced by grinding is not sufficient to decrease the crack length reached whereas effects of shot peening decrease highly these latter. So, there is a threshold of residual stress from which residual stresses are useful against cracking.     

Macroscopic and microscopic changes in the surface layers of annealed and case-hardened steel rollers due to rolling contact

Measurements of the residual stress and observations of the microstructure at the surface and in the subsurface of rollers were performed during rolling contact fatigue tests of annealed 0.45% carbon steel and case-hardened nickel-chromium steel rollers. Compressive residual stresses in annealed rollers were induced by the rolling contact. With case-hardened rollers they were induced by heat treatment prior to the rolling contact fatigue tests. After the rolling contact fatigue tests the compressive residual stresses on the surface of the annealed rollers and in the subsurface of the case-hardened rollers relaxed; a characteristic substructure was formed by the stress cycles, which caused surface failure. It was confirmed that the microcracks leading to surface failure initiate on the surfaces of annealed rollers and in the subsurface of case-hardened rollers.