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A hybrid finite element analysis of shot peen contour forming using residual stress measurements
Wagner, James Michael
Wagner, James Michael
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t13073_Wagner.pdf
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2013-07
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Abstract
In order to develop surfaces that have the proper curvature for aerospace structures, it is
sometimes necessary to use shot peen forming, also known as contour forming, to create the
desired shape in a piece of metal. Since the preferred metal in aerospace continues to be
aluminum and its alloys, this study will concentrate on the effects of shot peening on aluminum.
Typically, shot intensity is measured using standard Almen strips made from cold rolled
SAE 1070 spring steel. Since the effects of the shot on aluminum is the chief concern of this
study, aluminum strips of the same size and thickness will be used to determine the intensity of
the shot on aluminum parts. These strips will be exposed for different amounts of time to
different intensities, measured using the steel Almen strips, and then the intensity (or arc height)
will be measured on the aluminum strips. The residual stresses in these strips will then be
measured using the hole drill method (ASTM E837).
The stresses from the residual stress test will then be used to develop a finite element
model that simulates the aluminum strips and the deformation in them. The model will then be
calibrated with the empirical data. From there, it will be the goal of this study to be able to
predict the deformation of aluminum parts when exposed to certain shot peen intensities. This
will enable more efficient contour forming processes with less rework. Furthermore, the trial
and error of a manual process can be avoided with the use of robotics. Robotics/Automation can
also help in creating more consistent results.
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Thesis (M.S.)--Wichita State University, College of Engineering, Dept. of Mechanical Engineering.
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Wichita State University
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Copyright 2013 James Michael Wagner, Jr.