Finite element analysis of residual stress field induced by laser shock peening

The finite element method is applied to analyze the laser shock peening process (LSP) for thick parts (considered as a semi-infinite half space) and thin parts (finite thickness domain). The technology of LSP is used to enhance mechanical properties such as fatigue life, fretting fatigue life, resistance to stress corrosion cracking and surface hardness. These enhanced material properties are directly related to the magnitude and distribution of the plastic strain and associated residual stresses due to shockwaves induced by LSP. To reduce the process development cost and time, the prediction of residual stress field is very useful to provide a base design guideline for selecting appropriate LSP conditions for evaluation. An axisymmetric Finite Element Analysis (FEA) code, named SHOCKWAVE, is developed in order to complement shortcomings of applying commercial FEA codes at extremely high strain rates (as high as 104 −106/sec). The rate dependent plasticity theory is applied along with the small strain assumption. The solution process consists of an explicit dynamic loading analysis for shock loading stage and a static unloading analysis (implicit) to determine the equilibrium state for the residual stress and plastic strain fields. Some of the highlights explored in this investigation entail: (i) overstress power law models for the rate dependence, (ii) various hardening models, (iii) a second-order accurate implicit algorithm for the plastic consistency condition, (iv) an adaptively expanding domain scheme to trace the stress-free boundary condition in a simple way, (v) a special uniform meshing scheme to avoid the usual assembly process and repeated calculations for the stiffness matrix, (vi) mesh sensitivity study, (vii) comparisons with measured data provided and supported by the LSP Technologies, Inc.; The dynamic behavior of Ti-6Al-4V at high strain rates can be investigated by using the split torsional Hopkinson bar experiment and by a longitudinal shock loading simulation in uniaxial strain to obtain material parameters representing rate dependent plasticity. In case of the double-sided laser peening for a thin part, reversal in loading plays a significant role. The stress waves repeatedly recompose the pre-accumulated plastic strains because of the interaction of the primary and reflected stress waves. In an attempt to better represent the material behavior under repeated reversals and collapses in loading, a sequence of bend-reverse bend tests is performed to identify the material parameters of TI-6Al-4V needed for a nonlinear kinematic hardening model (Chaboche model). For a thick part (a semi-infinite domain), single shot as well as multiple shots (at the same location) cases are simulated and compared with measured data for two different loading magnitudes and three different hardening models. Some of the simulation results agree well with the measured data, depending on the choice of hardening model and the treatment of rate dependent material behavior at high strain rates. Only a single shot (on both sides) case is investigated for a thin part (a finite thickness domain) in terms of residual stress distribution. The disagreement between the computed results and the measured data is more pronounced in this case, needing further investigations on both sides of the fields.