Correcting distortions of thin-walled machined parts by machine hammer peening

Journal Article · 31 October 2023 · Chinese Journal of Aeronautics

DOI: https://doi.org/10.1016/j.cja.2023.10.023 · OSTI ID:2205053

Madariaga, Aitor  ^[1]; Cuesta Zabalajauregui, Mikel  ^[2]; Ortiz-De-Zarate, Gorka  ^[2]; Sáenz-De-Argandoña, Eneko ^[2]; Soriano, Denis ^[2]; Prime, Michael Bruce  ^[3]; Arrazola, Pedro José ^[2]

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1. Univ. of Manchester (United Kingdom)
2. Mondragon Univ. (Spain)
3. Los Alamos National Laboratory (LANL), Los Alamos, NM (United States)

Thin-walled aerostructural components frequently get distorted after the machining process. Reworking to correct distortions or eventually rejecting parts significantly increases the cost. This paper proposes a new approach to correct distortions in thin-walled components by strategically applying hammer peening on target surfaces of a machined component. Aluminium alloy 7475-T7351 was chosen for this research. The study was divided in two stages. First, the residual stresses (RS) induced by four different pneumatic hammer peening conditions (modifying the stepover distance and initial offset) were characterised in a test coupon, and one of the conditions was selected for the next stage. In the second stage, a FEM model was used to predict distortions caused by machining in a representative workpiece. Then, the RS induced by hammer peening were included in an FEM model to define two hammer peening strategies (varying the coverage area) to analyse the capability to reduce distortions. Two workpieces were machined and then treated with the simulated hammer peening strategies for experimental validation. Results in the test coupon showed that pneumatic hammer peening can generate high compressive RS (-50 to –350 MPa) up to 800 μm depth, with their magnitude increasing with a reduced stepover distance. Application of hammer peening over 4% of the surface of the representative workpiece reduced the machining-induced distortions by 37%, and a coverage area of 100% led to and overcorrection by a factor of five. This confirms that hammer peening can be strategically applied (in target areas and changing the percentage of coverage) to correct low or severe distortions.

• Research Organization: Los Alamos National Laboratory (LANL), Los Alamos, NM (United States)
• Sponsoring Organization: USDOE National Nuclear Security Administration (NNSA)
• Grant/Contract Number: 89233218CNA000001
• OSTI ID: 2205053
• Report Number(s): LA-UR--23-23265
• Journal Information: Chinese Journal of Aeronautics, Journal Name: Chinese Journal of Aeronautics Journal Issue: 6 Vol. 37; ISSN 1000-9361
• Publisher: ElsevierCopyright Statement
• Country of Publication: United States
• Language: English