Shot Peen Flattening Model Inversion for Accurate Forming Paths
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Solution Overview
Problem
Current methods for obtaining an initial flattened model in shot peening forming processes are inaccurate and inefficient, failing to account for material expansion, leading to misalignment and requiring laborious trial-and-error corrections.
Innovation Solution
An inverse simulation method using finite element simulation software to generate a body model, apply a stress field to an Almen-like strip, adjust until deformation matches shot peening test results, and perform a reversal operation to obtain an inverted stress field, considering process parameters and engineering experience for accurate initial flattened models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the one-step method is used to obtain the initial flattened model, then the process is simple and quick, but the accuracy of the flattened model is poor due to not considering material expansion
Solution Approach 1:
The patent performs preliminary simulation calculation before actual shot peening forming to predict material expansion. By calculating the expansion amount in advance and compensating it in the initial flattened model, the method eliminates the need for trial-and-error corrections, thus improving both accuracy and overall efficiency.
Solution Approach 2:
The patent uses simulation results as feedback to optimize the initial flattened model. The simulation predicts expansion based on process parameters, and this information is fed back to adjust the flattening amount, creating a closed-loop system that improves accuracy without requiring multiple physical trials.
2Manufacturing precision
If trial and error method is used to correct the initial flattened model after flattening, then the accuracy can be improved, but the process becomes time-consuming and laborious
Solution Approach 1:
The patent performs preliminary simulation calculation before actual shot peening forming to predict material expansion. By calculating the expansion amount in advance and compensating it in the initial flattened model, the method eliminates the need for trial-and-error corrections, thus improving both accuracy and overall efficiency.
Solution Approach 2:
The patent replaces the physical trial-and-error mechanical correction process with computational simulation. Instead of repeatedly manufacturing and testing physical models, the system uses finite element simulation to predict and correct expansion, significantly reducing time and labor.
3Device complexity
If process parameters and process path are separated from flattening determination, then the planning is simpler, but it is impossible to obtain an accurate initial flattened model for shot peening forming process
Solution Approach 1:
The patent merges the determination of process parameters, process path, and initial flattened model into a unified simulation framework. By considering all three factors together in the simulation calculation, the system captures their interrelationships and determines an accurate initial flattened model that is specifically tailored to the selected process parameters and path.
Solution Approach 2:
The patent creates a comprehensive simulation system that simultaneously handles multiple functions: determining process parameters, planning process path, and calculating initial flattened model. This multi-functional approach allows all planning aspects to be optimized together rather than separately.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and accurate determination of process parameters and paths for shot peening, ensuring reliable initial flattened models and improved efficiency in shot peening forming processes.
Implementation Method 1
applying a stress field onto the model of Almen-like strip in a finite element simulation software to perform a simulation-based deformation calculation
Implementation Method 2
the deformation is achieved by the expansion of material. It has been proven in practice that the flattening without considering the shot peening forming process
Data Source
Figure 1~2A
Figure 2B~4B
Figure 4C
AI summary
The present disclosure provides an inverse simulation method for obtaining an initial flattening model for a shot peening forming process, comprising: on the basis of an actual digital model of a target formed part, using computer software to generate a body model and construct a consistent Almen-like strip model; applying a stress field onto the Almen-like strip model in finite element simulation software to perform simulation deformation calculation, continuously adjusting the magnitude of the stress field until calculated deformation is consistent with deformation of an Almen-like strip after a shot peening forming test under selected shot peening process parameters, and determining a corresponding equivalent induced stress field model on this basis; then performing an inversion operation on the equivalent induced stress field model to obtain a reverse stress field; and applying the reverse stress field onto the body model according to a planned process path so as to perform inverse simulation calculation to obtain an initial flattening model, and on the basis of shot peen process parameters corresponding to the applied path and the stress field, obtaining a shot peen process scheme matched with the flattening model.