Shot Peening - Fatigue & Residual Stresses

TANUJ DESHMUKH
Laboratoire de mécanique multi-échelles July,2019

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 Introduction - Fatigue Failure

● The prediction and prevention of failure of components and structures are the basis
of sound engineering and is essential for safe execution of our daily life.

● Engineering failure can occur in many ways like elastic fracture, brittle fracture,
fatigue, creep and stress, etc.

● Most engineering components and structures

are subjected to complex loading conditions
where stress–strain cycles fluctuate with time
which leads to fatigue failure.

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 Introduction - Fatigue Failure
● Components which undergo fluctuating stress and strains tend to fail at stress much lower than
statically loaded.

● Fluctuating stresses and strains cause progressive, localised and permanent microstructural
changes in structure .

● These microstructural changes may culminate in the formation of cracks and their subsequent
growth to a size which causes final fracture after a sufficient number of stress or strain
fluctuations .

● Permanent microstructural changes are mainly due to cyclic plastic deformations and cause
irreversible changes in substrate . Fatigue results from cyclic plastic deformation in every
instance.

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 Why is fatigue failure our concern ?

• When machine parts fail statically, they usually develop a very large deflection,
because the stress has exceeded the yield strength, and the part is replaced
before fracture actually occurs.

• Thus many static failures give visible warning in advance.

• But a fatigue failure gives no warning! It is sudden and total, and hence
dangerous.

• It is relatively simple to design against a static failure, because our knowledge is

comprehensive whereas fatigue is a much more complicated phenomenon.

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 Stages of Fatigue Failure

The fatigue fracture arises from 3 stages of development :

Stage I : Initiation of one or more microcracks

due to cyclic plastic deformation followed by crystallographic
Propagation extending from two to five grains about the origin.
Stage I cracks are not normally discernible to the naked eye.

Stage II :Progresses from microcracks to macrocracks forming

parallel plateau-like fracture surfaces separated by
longitudinal ridges.

Stage III : Occurs during the final stress cycle when the remaining material cannot
support the loads, resulting in a sudden, fast fracture. A stage III fracture can be brittle,
ductile, or a combination of both.
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 Primary Objective

Keep in Mind : As Engineers our primary objectives are :-

• Avoiding sudden fractures

• Improving Fatigue Life

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 Residual Stresses

Why did we suddenly switched to residual stresses ?

- Fatigue life of a components depends on a number of parameters like Loading Surface

conditions , Notch Sensitivity, Temperature, Reliability , Residual Stress etc

- Residual stresses have a significant influence on the fatigue lives of engineering components[Ref.]
and that’s why we are interested in them.

What are residual stress ?

- Residual stresses are the stresses produced in a body when it undergoes non uniform
plastic deformation.

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 How do Residual Stresses arise ? (Physics)
Residual stresses arise when plastic deformation is not uniform
throughout the entire cross section of the part being deformed.

Consider a metal specimen where the surface has been deformed in

tension by bending so that part of it has undergone plastic deformation.

When the external force is removed, the regions which have been plastically
deformed prevent the adjacent elastic regions from undergoing complete
elastic recovery to the unstrained condition.Thus, the elastically deformed
regions are left in residual tension.

The regions which were plastically deformed must be in a state of residual compression to balance
the stresses over the cross section of the specimen.

In general, for a situation where part of the cross section is deformed plastically while the
rest undergoes elastic deformation, the region which was plastically
deformed in tension will have a compressive residual stress after unloading,
while the region which was deformed plastically in compression will
have a tensile residual stress when the external force is removed. 8/Tanuj Deshmukh
 Supplementary Information on Plastic strain

Stress-strain relationship : The total true strain ∈t in a tension test is seprated into
elastic and plastic component :
1. Linear elastic strain ∈e : That portion of strain which is recovered upon unloading.

2. Plastic strain (nonlinear) ∈p : That portion of strain which cannot be recovered upon
unloading

∈t = ∈e + ∈p ………. (1)
∈e = σ / E ……………..(2)
∈t = σ / E +(σ / K)1/n where k- strength coefficient

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 Residual Stresses (Mechanical)

Now we understand the physics behind

“How residual stresses are generated in a object ?”

Lets try understand the residual stresses from mechanical point of view :

Residual stresses are inescapable consequence of manufacturing and fabrication process.

Conventional heat treatment processes like annealing, tempering, quenching etc are
likely to induce tensile residual stress in the treated material.

So what’s the problem with theses Tensile Residual Stress ?

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 Tensile Residual Stress VS Compressive Residual Stress

• Tensile residual stress often lead to rapid crack initiation and low cycle fatigue which
results in premature failure of engineering components.

• Whereas compressive residual stress tend delay the crack initiation and also tries to
shrink the pre existing crack(if any) thereby improving the fatigue life.

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 Fatigue Life Improvement

• To improve fatigue life of component we should try to avoid tensile residual stress
and have compressive residual stress.

• This can be achieved by imparting additional residual stresses using various

methods.

METHODS OF INDUCING RESIDUAL STRESSES

1. Mechanical Methods
2. Thermal Methods
3. Plating
4. Machining

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*Only Mechanical Methods are discusses in the ppt
 Mechanical Methods

The most widely used mechanical methods for producing compressive surface residual
stress for enhancing fatigue life are :
1. ROLLING
-Pressure of narrow rolls is used for creating
Plastic deformation

2. SHOT PEENING
- Kinetic energy of impact of small balls is used
for plastic deformation

Both methods use local plastic deformation to generate

compressive stresses.

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 Fun Fact

Deep cold rolling(DCR) offers several advantage over shot peening process like
- Deeper layer of compressive stress
- Better surface finish
- Cheaper than shot peening

But still shot peening is widely preferred in industry. Why ?

-DCR is limited to only a specific kind of geometry

And applying it to complex geometry is difficult
-DCR cannot be used for thin and intricate shapes

Since shot peening generated compressive residual stresses, which in turn

would increase fatigue life, Let’s explore more on Shot peening

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 REFERENCES

Machine Design By Shigley

Mechanical Metallurgy By Dieter