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Repeening Ing. Chichi en PDF
Repeening Ing. Chichi en PDF
Technical Sponsors:
Double peening and re-peening; techniques to
increase fatigue behaviour of new and used gears
Dr.Ing. F. Chichi
2Effelab srl
f.chichi@2effelab.it
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SHOT PEENING
Following actual trend, shot peening is one of most useful technique to increase gear serviceability
Generally speaking, Shot peening is a technique based on impact of spherical media accelerated toward surface
of component , with a speed range from 30 m/s up to 140 m/s .
Scope of process is to generate a plastic deformation on component surface, to produce compressive residual
stress under surface
Shot peening is a well known technique, so it’s useless to spend time to explain it: it’s enough to remember
shot peening effect on component surface
• hardening
•Metallurgical change
•Compressive residual stress down to 20 – 800 mm
•Surface finishing
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Those effect can be tuned by
•Media material
•Media dimension
•Impact speed
•Impact degree
•Coverage
Introducing shot peening, it was defined as a technique able to increase gear serviceability , not only
fatigue strength, because of
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SHOT PEENING AND FATIGUE BEHAVIOUR
Fatigue failure happens on component subjected to cyclic loading, each load being much less than the yeld
stress limit of the material under static condition
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These steps happen at different depth from surface
First second
stage stage
Third
stage
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As well known , fatigue strength enhancement by shot peening is related to 2 different mechanism
Generally speaking, for an high strength steel subject to a low duty - high number of cycles mission
profile (as usual for gears) fatigue strength improvement is within 30% - 50%
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If shot peening is a well know process, its improvement by double - step application is matter of
research.
If second step peening is done after the component was subject to use , the technique is called RE-
PEENING
If second step peening is done immediately after the first one, the technique is called DOUBLE PEENING
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RE-PEENING
By our experiences, Re-Peening is a useful technique to recover fatigue damage on gears, but only
in case of specific condition of
•Load spectrum
•Percentage of residual life still expected
If component has low duty - high number of cycles mission profile, without peak stress greater than
130% of fatigue limits, to perform a re-peening of component after a service life smaller than 75%
of expected service life can increase residual service life up to 80% of “as new” shot peened
component
It means that if a shot peened component have an expected service life equal to 100 , performing a
re-peenign after it spent 70% of its service life, new residual service life will be increased up to 80%
of expected service life for “as new” component, achieving a total service life equal to
70 + 80 = 150%
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REMARKS
• residual life enhancement is obtained by shot peening parameter different from those adopted
for shot peening on new component : for carburized gear media dimension roughly equal to 25%
and Almen intensity about half of those adopted for first peening seems to be the more adequate.
•No residual life enhancement is observed when mission profile includes stress greater than 75% of
yeld strength.
•Re-peening of component after a service life shorter than 40% of whole expected service life
seems to have no any effect on residual service life.
•Re-peening of components after a service life greater than 80% of whole expected service life
seems to have a detrimental effect on residual service life
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peened Re-peened after Re-peened after Re-peened
50% of 70% of after 80% of
expected expected expected
service life service life service life
From a theoretical point of view, it should be that , because of crack enucleation happens within
deepth of 5 – 10 mm where shot peening act by plasticization, re-peening is able to “close” any micro -
crack already present within this layer
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DOUBLE PEENING
Double Peening is a technique much more “young” than re-peening : start point for us was a paper
recently published :“High Strength and Compactness of Gears by WHSP (Double Hard Shot Peening)
Technology” by S. Matsumura -N. Hamasaka [1].
12
MPa
mm
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Following compressive residual stress improvement, also fatigue strength is reported as improved
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Our tests were performed on a steel 0,20% Carbon , peened after carburizing , and aim of our
analysis was to investigate if
• it is possible to combine effect of peening with different media to obtain a residual stress profile
combination of residual stress profile of each peening alone
• if so, investigate if order of peening is significant
• if so, investigate if fatigue strength enhancement is obtained
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As first screening, only 2 different media were adopted , F 0,8mm e F 0,1mm as in paper [1]
Given that it was not possible for us to have a “flat” residual stress profile as reported in paper [1],
our test confirm that residual stress profile obtained by a sequence of shot peening process, having
each one process alone residual stress profile clearly different in terms of shape versus depth, can
have a final residual stress shape combination of single shape
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MIXING OF MEDIA
Given that process parameter for peening with F 0,8mm and F 0,1mm media are different, 3
different tests were performed adopting respectively
ORDER OF PEENING
Significative result can be obtained only if first peening is performed with media characterized by
“deeper “ profile
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FATIGUE STRENGHT
Also in the “best case” , fatigue strength enhancement is not very significative in respect of performance
obtained by components subject to shot peening process having highest residual stress value
160
140
120
100
80
60
40
20
0
No
componente pallinatura 0,8
F 0,8mm
pallinatura 0,1
F 0,1mm F 0,1 + F 0,8
combinazione F 0,8 first
sequenza 0,8 + F 0,1 first
+ 0,1 sequenza 0,1 ++0,8
originale
peening peening peening mm mixed F 0,1 before F 0,8 before
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REMARKS
About re-peening of gear, our experiences confirm that this techniques, in presence of low duty –
high number of cycles mission profile , can improve total service life up to 50% when performed on
components having spent from 40% up to 70 % of whole expected service life
No any improvement is obtained when mission profile includes high stress or when second peening
is performed on components having spent less than 40% of expected service life
Worsening is obtained when second peening is performed on components having spent more than
80% of whole expected service life
About double peening of gear, our experiences confirm that is possible to “combine” residual stress
profile obtained by different peening process when distribution versus depth is clearly different ,
but in any case fatigue strength increase is not so significant in respect of “best case” of single shot
peening , but of course in this case our experience is still quite limited
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