CN118153382A - Thin-wall blade shot peening process parameter determination method based on damage control - Google Patents

Thin-wall blade shot peening process parameter determination method based on damage control Download PDF

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CN118153382A
CN118153382A CN202410272422.8A CN202410272422A CN118153382A CN 118153382 A CN118153382 A CN 118153382A CN 202410272422 A CN202410272422 A CN 202410272422A CN 118153382 A CN118153382 A CN 118153382A
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shot
thin
blade
speed
maximum
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姚倡锋
谭靓
陈俊霖
范滔
孙蕴齐
曹艺隆
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Northwestern Polytechnical University
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Northwestern Polytechnical University
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Abstract

The invention relates to a thin-wall blade shot peening process parameter determination method based on damage control, which comprises the steps of firstly adopting three structures of an air inlet side, a blade body or an air outlet side corresponding to each single shot finite element model of the same shot to collide with the thin-wall blade at the same speed to determine the most damaged structure, then using the same shot to determine the maximum shot speed which does not generate damage and the pit diameter at the speed from the most damaged structure to the most damaged structure, then using the same shot to determine the maximum shot quantity which does not generate damage from the blade body of the multi-shot random shot peening finite element model with the same shot quantity as less as more, then calculating air pressure based on the maximum shot speed which does not generate damage, determining the maximum shot peening intensity based on the air pressure through an Almen test, and calculating the maximum coverage rate according to the maximum shot quantity and the pit diameter at the maximum shot speed. The method can calculate the maximum shot blasting strength and coverage rate of the thin-wall blade during shot blasting strengthening.

Description

Thin-wall blade shot peening process parameter determination method based on damage control
Technical Field
The invention relates to the technical field of shot blasting processes, in particular to a thin-wall blade shot blasting strengthening process parameter determining method based on damage control.
Background
Shot blasting is an important method for strengthening parts of an aeroengine, and parts such as gears, main and auxiliary connecting rods, compressors, turbine blades and the like of an airplane are treated by adopting a shot blasting process. Residual compressive stress is generated on the surface of the part after shot blasting, and proper residual compressive stress can improve the overall performance of the part, enhance the capability of resisting external damage, and prolong the fatigue life. The blade has a complex structure and high shape precision, and the shot blasting process needs to be controlled strictly, so that shot blasting process parameters are important factors affecting the strengthening effect.
Because the inlet/outlet edges of the thin-wall blade are sharp, the material has weak anti-shot striking capability, and the shot blasting under larger parameters easily damages the edge parts of the thin-wall blade, induces microcracks and reduces the anti-fatigue capability of the thin-wall blade. Therefore, there is a need for a method that can determine the maximum shot peening process parameters for thin wall blade structures.
Disclosure of Invention
Based on the method, the invention provides a thin-wall blade shot peening process parameter determination method based on damage control, and the maximum shot peening intensity and coverage rate of the thin-wall blade during shot peening can be determined.
The invention provides a thin-wall blade shot peening process parameter determination method based on damage control, which comprises the following steps:
Establishing a single-pellet finite element model of an air inlet edge, a blade body and an air outlet edge of the thin-wall blade, and adopting the same pellets to collide with the air inlet edge, the blade body or the air outlet edge corresponding to each single-pellet finite element model at the same speed to determine the most damaged structure of the thin-wall blade;
Using the same projectile to collide with the structure which is most easily damaged by the thin-wall blade from small to large, obtaining plastic deformation cloud pictures of the structure which is most easily damaged by the thin-wall blade at different speeds, determining the maximum projectile speed without damage according to the plastic deformation cloud pictures at different speeds, and measuring the diameter of the projectile pit at the maximum projectile speed without damage;
Establishing a multi-shot random shot blasting finite element model in a blade body area of the thin-wall blade;
The same shots with the number from small to large are used for striking the blade bodies of the multi-shot random shot blasting finite element model, and the maximum shot number without damage is determined according to the plastic deformation simulation results under different shot numbers;
The air pressure is calculated according to the maximum shot speed, the maximum shot strength is determined through an Almen test based on the air pressure, and the maximum coverage rate is calculated according to the maximum shot number and the diameter of the pit at the maximum shot speed, wherein the diameter and the flow rate of the shots are constant.
In one embodiment, building a single shot finite element model of the inlet, body and outlet edges of a thin-walled blade includes:
establishing a single shot geometric model of an air inlet side, a blade body and an air outlet side according to a thin-wall blade structure based on a real proportion;
Giving density, elastic modulus and poisson ratio to the single-shot geometric model of the air inlet side, the blade body and the air outlet side to obtain the single-shot elastic geometric model of the air inlet side, the blade body and the air outlet side;
Setting Johnson-Cook intrinsic parameters and Johnson-Cook damage parameters for single shot elastic geometric models of an air inlet side, a blade body and an air outlet side;
Setting shot parameters, contact properties and boundary conditions for a single shot elastic geometric model of a feeding edge, a blade body and an exhaust edge;
And carrying out grid division on the single-pellet elastic geometric models of the air inlet side, the blade body and the air outlet side by adopting different unit types to obtain the single-pellet finite element models of the air inlet side, the blade body and the air outlet side.
In one embodiment, after the same projectile collides with the air inlet side, the blade body or the air outlet side corresponding to each single projectile finite element model at the same speed, the structure corresponding to the single projectile finite element model with the plastic deformation degree is the structure of the thin-wall blade which is most easily damaged.
In one embodiment, a multi-shot random shot blasting finite element model is built in a blade body area of a thin-wall blade, a block of area is selected as a target area in the blade body area of the thin-wall blade, parameter setting and grid division are carried out in the target area, a plurality of identical shots are randomly generated in the selected target area, and the speed of each shot is given to be the maximum shot speed.
In one embodiment, the air pressure is calculated by a shot velocity empirical formula, which is:
wherein v s is the pellet speed, p is the air pressure, d is the pellet diameter, and q is the flow.
In one embodiment, the coverage is calculated by the bolus quantity formula:
Where n is the number of shots, S is the area of the impact area, C (n) is the coverage, and r is the pit radius.
The invention has the beneficial effects that: according to the invention, through finite element simulation analysis, the maximum shot quantity and the maximum shot speed of the thin-wall blade without damage and the pit diameter under the speed are determined, and then the maximum shot strength and coverage rate of the thin-wall blade during shot peening strengthening can be calculated based on the maximum shot speed, the pit diameter under the speed and the maximum shot quantity.
Drawings
FIG. 1 is a flow chart of a method for determining parameters of a thin-wall blade shot peening process based on damage control in an embodiment of the invention;
FIG. 2 is a schematic flow chart of a single shot finite element model for building the inlet, body and outlet sides of a thin-walled vane in accordance with another embodiment of the present invention;
FIG. 3 illustrates three exemplary structural geometric models of the inlet side, the blade body and the outlet side of a thin-walled blade in an embodiment of the present invention;
FIG. 4 is a schematic diagram of meshing of three single shot finite element models of thin-walled blades in an embodiment of the present invention;
FIG. 5 is a schematic diagram of plastic deformation of different single shot finite element models under fixed speed single shot peening, wherein FIG. 5 (a) is a schematic diagram of plastic deformation of an intake side finite element model under fixed speed single shot peening, FIG. 5 (b) is a schematic diagram of plastic deformation of an exhaust side finite element model under fixed speed single shot peening, and FIG. 5 (c) is a schematic diagram of plastic deformation of a leaf depth finite element model under fixed speed single shot peening;
FIG. 6 is a schematic view of plastic deformation of an intake side single shot finite element model under different speed single shot impact in an embodiment of the invention, wherein FIG. 6 (a) is a schematic view of plastic deformation under single shot impact at speed 25m/s, FIG. 6 (b) is a schematic view of plastic deformation under single shot impact at speed 30m/s, FIG. 6 (c) is a schematic view of plastic deformation under single shot impact at speed 35m/s, and FIG. 6 (d) is a schematic view of plastic deformation under single shot impact at speed 40 m/s;
FIG. 7 is a schematic diagram of a cracking phenomenon occurring when a relatively high-speed single shot impacts an intake edge structure in an embodiment of the present invention;
FIG. 8 is a schematic diagram of a model of random peening of a blade portion in an embodiment of the present invention;
FIG. 9 is a random shot script writing flow in an embodiment of the invention;
Fig. 10 is a schematic view of plastic deformation of the impact blade body of different numbers of shots in the embodiment of the present invention, wherein fig. 10 (a) is a schematic view of plastic deformation of 30 shot impact blade bodies, fig. 10 (b) is a schematic view of plastic deformation of 50 shot impact blade bodies, fig. 10 (c) is a schematic view of plastic deformation of 70 shot impact blade bodies, and fig. 10 (d) is a schematic view of plastic deformation of 90 shot impact blade bodies;
FIG. 11 is a cloud graph of stress and plastic deformation of a random peen impinging blade-body structure in an embodiment of the invention.
Detailed Description
The present invention will be described in further detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
In one embodiment, as shown in fig. 1, fig. 1 is a flow chart of a method for determining a thin-wall blade peening process parameter based on damage control according to an embodiment of the present invention, where the method for determining the thin-wall blade peening process parameter based on damage control includes the following steps:
s101, establishing a single-pellet finite element model of the air inlet edge, the blade body and the air outlet edge of the thin-wall blade, and adopting the same pellets to collide with the air inlet edge, the blade body or the air outlet edge corresponding to each single-pellet finite element model at the same speed to determine the most damaged structure of the thin-wall blade.
Specifically, the same projectile collides with the air inlet edge corresponding to the single projectile finite element model of the air inlet edge at the same speed, the blade body corresponding to the single projectile finite element model of the blade body and the air outlet edge corresponding to the single projectile finite element model of the air outlet edge are adopted.
After the same projectile collides with the air inlet side, the blade body or the air outlet side corresponding to each single projectile finite element model at the same speed, the structure corresponding to the single projectile finite element model with the plastic deformation degree is the structure of which the thin-wall blade is most easily damaged.
S102, using the same projectile to collide with a structure which is most easily damaged by the thin-wall blade from a small speed to a large speed, obtaining plastic deformation cloud pictures of the structure which is most easily damaged by the thin-wall blade at different speeds, determining the maximum projectile speed without damage according to the plastic deformation cloud pictures at different speeds, and measuring the diameter of the projectile pit at the maximum projectile speed without damage.
S103, establishing a multi-shot random shot blasting finite element model in a blade body area of the thin-wall blade, so as to calculate the accuracy of coverage rate.
Specifically, a multi-shot random shot blasting finite element model is established in a blade body area of the thin-wall blade, a block of area is selected as a target area in the blade body area of the thin-wall blade, parameter setting and grid division are carried out in the target area, a plurality of identical shots are randomly generated in the selected target area, and the speed of each shot is given to be the maximum shot speed.
In this embodiment, the parameter setting and grid division in the target area are consistent with step S101, and the random generation of a plurality of identical shots is completed in the target area using Python syntax.
S104, using the same shot with a small number to strike the blade body of the multi-shot random shot blasting finite element model, and determining the maximum shot number without damage according to plastic deformation simulation results under different shot numbers.
S105, calculating air pressure according to the maximum shot speed, determining the maximum shot blasting strength through an Almen test based on the air pressure, and calculating the maximum coverage rate according to the maximum shot quantity and the pit diameter under the maximum shot speed, wherein the diameter and the flow rate of the shots are constant.
Specifically, the air pressure is calculated by a shot peening speed empirical formula, which is:
wherein v s is the pellet speed, p is the air pressure, d is the pellet diameter, and q is the flow.
In one embodiment, the coverage is calculated by the bolus quantity formula:
Where n is the number of shots, S is the area of the impact area, C (n) is the coverage, and r is the pit radius.
According to the embodiment, the maximum shot blasting strength and the maximum coverage rate of the thin-wall blade can be determined through a finite element simulation method.
In one embodiment, as shown in fig. 2, fig. 2 is a schematic flow chart of a single pellet finite element model for establishing an air inlet side, a blade body and an air outlet side of a thin-walled blade in the embodiment of the present invention, and the embodiment relates to how to establish a single pellet finite element model for establishing an air inlet side, a blade body and an air outlet side of a thin-walled blade, where the single pellet finite element model for establishing an air inlet side, a blade body and an air outlet side of a thin-walled blade includes:
S201, establishing a single shot geometric model of an air inlet side, a blade body and an air outlet side according to a thin-wall blade structure based on a real proportion.
S202, giving density, elastic modulus and Poisson' S ratio to the single-shot geometric model of the air inlet side, the blade body and the air outlet side to obtain the single-shot elastic geometric model of the air inlet side, the blade body and the air outlet side.
S203, setting Johnson-Cook constitutive parameters and Johnson-Cook damage parameters for the single-shot elastic geometric model of the air inlet side, the blade body and the air outlet side.
Specifically, the Johnson-Cook constitutive parameters and Johnson-Cook damage parameters are:
wherein sigma is the stress of the material, epsilon is the equivalent plastic strain, Is equivalent strain rate,/>For reference strain rate, T is the material temperature, T m is the melting point temperature of the material, T r is the ambient temperature, and A, B, C, n, m is the constitutive parameter.
Johnson-Cook injury parameters were:
Where ε f is the strain to failure of the material, σ m is the hydrostatic stress, D 1~d5 is the damage parameter, which is the equivalent stress.
S204, setting shot parameters, contact properties and boundary conditions for the single shot elastic geometric model of the air inlet side, the blade body and the air outlet side.
S205, carrying out grid division on the single-pellet elastic geometric model of the air inlet side, the blade body and the air outlet side by adopting different unit types to obtain the single-pellet finite element model of the air inlet side, the blade body and the air outlet side.
In a specific embodiment, ABAQUS is adopted to carry out shot peening finite element simulation analysis of different structures of the thin-wall blade, ceramic shots are used as shots, and the maximum shot peening intensity and coverage rate in shot peening process parameters of the thin-wall blade are determined based on damage control. The method comprises the following specific steps:
(1) As shown in fig. 3, a single shot geometric model of three typical features of the blade body, the air inlet side and the air outlet side is established according to actual proportion, and density, elastic modulus and poisson ratio are given to all geometric models. Considering that the thin-walled blade can be subjected to severe plastic deformation and damage in the shot peening process, the Johnson-Cook constitutive parameters and the Johnson-Cook damage parameters are set for three characteristic structures of the blade by combining the actual performance of the superalloy.
Then, pellet parameters, contact properties and boundary conditions are set for the single pellet elastic geometric model of the intake side, the blade body and the exhaust side. Specifically, the ceramic pellet used had a diameter of 0.3mm, a vickers hardness of 700HV1, and an elastic modulus of 390GPa, which is far greater than that of the test piece to be sprayed, so that the pellet was set as a rigid body. A reference point is created at the centre of the projectile and the total mass of the projectile is applied to the reference point, the speed of the projectile ejection being set by controlling the speed of the reference point. In setting the contact properties, the test piece surface is impacted with a circular arc-shaped dimple, thus defining the contact type of the shot blasting process as a face-to-face contact, setting the shot as a master contact face, and setting the impacted feature as a slave contact face. The tangential and normal behavior between the two contact surfaces are controlled using a penalty function, and the coefficient of friction is set to 0.3. When the boundary condition is set, the shot is constrained to have the freedom degree in the speed direction only, and the other surface of the shot blasting surface of the test piece is set to be completely constrained, so that the freedom degrees in six directions are limited.
In order to improve the operation speed, a single-pellet elastic geometric model of an air inlet side, a blade body and an air outlet side is subjected to grid division by adopting a partition and layering division method. As shown in FIG. 4, the position of the near-surface area I is impacted by the projectile, the stress strain change is obvious, a refined grid is used, the stress field of the position II of the middle area is further diffused, the grid size is centered, the lowest area III mainly plays a role in fixing and balancing the stress, and a large-size grid is used. The projectile is of a regular sphere curved surface structure, a sweep grid mainly comprising quadrangles is adopted, and the unit types are R3D4 and R3D3; the blade body model is of a regular cuboid structure, a hexahedral structure grid is adopted, and the unit type is C3D8R; the structure of the air inlet side and the air outlet side is complex, a tetrahedral free grid is adopted, and the cell type is C3D10M.
As shown in FIG. 5, the fixed speed single shot peening simulation analysis was performed on the inlet side, the outlet side and the blade body structure of the blade, and the three feature structures were impacted at the same speed of 40m/s, and the pit diameter generated after the inlet side peening was found to be the smallest but the most severe plastic deformation part. The method is characterized in that the air inlet edge structure is sharp, the constraint of materials around the tip position is small, the shot rapidly generates larger displacement after impacting the contact part, and further, the plastic deformation is generated to a greater extent, so that the subsequent single shot simulation analysis is carried out on the air inlet edge structure.
(2) Four plastic deformation cases obtained by striking the intake side structure with the same single shot of 25m/s, 30m/s, 35m/s and 40m/s, respectively, are shown in FIG. 6. It can be seen that as the velocity of the projectile increases, the diameter of the pit formed at the tip of the air inlet side and the maximum deformation depth increase. Even a 50m/s single shot impact on the air inlet side structure can cause cracking phenomenon on the surface of the component, and as shown in figure 7, the grid which is embodied as the impact area of the air inlet side component is distorted or missing.
Considering extreme cases such as out-of-tolerance in profile, stress concentration, damage to a thin-walled blade structure, and the like caused by the impact of shots with excessive speed, the maximum shot impact speed is determined by analyzing the plastic deformation degree at different speeds with the limit of the plastic deformation degree without damaging the blade, with the aim of ensuring the strengthening effect of the blade during shot blasting. Thus the maximum pellet velocity without damage in this example was 40m/s.
(3) In an actual shot blasting process, a large number of random shots strike the surface of a material at a high speed in a short time, and the process is more complicated than a single shot. The shot blasting coverage rate refers to the percentage of the surface bullet mark of the part after shot blasting reinforcement to the total area, so that a 0.3×0.3mm area is selected at the blade body part for random shot blasting reinforcement in consideration of the accuracy of the calculated coverage rate, and as shown in fig. 8, the settings of the used material parameters, the table division and the like are consistent with the modeling process of the step 1.
The established random shot blasting model flow is shown in fig. 9, after the coordinate range of the shot blasting area is determined, three-dimensional random coordinates are generated by utilizing a random function of Python language, whether the distance between each generated random coordinate and the existing coordinate is interfered or not is judged, and coordinate values which do not interfere are stored until the number of generated coordinates is equal to the number n of shots required by a certain set coverage rate. To ensure that the calculated coverage of the selected region of the blade body part is the maximum coverage, the maximum pellet velocity obtained in step 2 is applied to the reference points of the n pellets generated.
(4) Shot peening of 30, 50, 70 and 90 shot sizes is performed on selected areas of the blade body structure (She Shenshan shot finite element model) as shown in fig. 10. It was found that plastic deformation occurs at different positions, the unevenness of the reinforced region gradually increases as the number of shots increases, and the shot blast profile becomes uneven due to mutual extrusion of materials, and the generated pit region is large, but the depth is shallow, and stress concentration is easily generated.
And extracting the residual stress result of the central point of the reinforced area, wherein the residual stress is gradually increased when the shot quantity required by shot blasting is gradually increased. However, when the number of shots is 110, the extracted residual stress does not change much from the residual stress corresponding to the number of 90 shots, and a cracking phenomenon occurs on the sample surface when one of the shots hits the member, so that the fatigue life is reduced, as shown in fig. 11. Thus, a maximum tolerance shot size is determined taking into account whether random shots at different shot sizes damage the surface of the strengthened member. The maximum number of shots that did not cause damage as determined in this example was 90.
(5) And calculating the maximum coverage rate required by shot blasting by using a shot quantity formula. The coverage rate was calculated according to the pellet number formula, the maximum number of pellets which did not cause damage as determined in this example was 90, and after the maximum speed which did not cause damage was obtained by step (2), the diameter of the pit was 79 μm on the blade body, and the number of pellets corresponding to 98% coverage rate was 73.
n=72.44≈73
When the coverage rate reaches 98%, it is generally considered that 100% full coverage is achieved. If it is desired to calculate the coverage for other shot numbers, the number of shots is divided by the number of shots corresponding to 98% coverage, for example, 90 shots corresponds to a coverage of
The fixed shot flow rate used in this example was 1.5kg/min, the shot was Z300 ceramic shot, and the diameter was 0.3mm. The air pressure was calculated using an empirical formula for shot velocity, and the maximum shot velocity selected to be free from damage in this example was 40m/s, and the air pressure was 1.5bar by empirical calculation for shot velocity.
p=1.49≈1.5
Then, the arc height value of the impact Almen test piece under the air pressure is obtained through test calculation by using an arc height meter, so that the maximum shot blasting strength is obtained.
The foregoing examples illustrate only a few embodiments of the invention and are described in detail herein without thereby limiting the scope of the invention. It should be noted that it will be apparent to those skilled in the art that several variations and modifications can be made without departing from the spirit of the invention, which are all within the scope of the invention. Accordingly, the scope of the invention should be assessed as that of the appended claims.

Claims (6)

1. A method for determining parameters of a thin-wall blade shot peening process based on damage control is characterized by comprising the following steps:
Establishing a single-pellet finite element model of an air inlet edge, a blade body and an air outlet edge of the thin-wall blade, and adopting the same pellets to collide with the air inlet edge, the blade body or the air outlet edge corresponding to each single-pellet finite element model at the same speed to determine the most damaged structure of the thin-wall blade;
Using the same projectile to collide with the structure which is most easy to damage of the thin-wall blade from small to large, obtaining plastic deformation cloud pictures of the structure which is most easy to damage of the thin-wall blade at different speeds, determining the maximum projectile speed without damage according to the plastic deformation cloud pictures at different speeds, and measuring the diameter of the projectile pit at the maximum projectile speed without damage;
Establishing a multi-shot random shot blasting finite element model in a blade body area of the thin-wall blade;
The same shots with the number from small to large are used for striking the blade bodies of the multi-shot random shot blasting finite element model, and the maximum shot number without damage is determined according to the plastic deformation simulation results under different shot numbers;
And calculating air pressure according to the maximum shot speed, determining the maximum shot blasting strength through an Almen test based on the air pressure, and calculating the maximum coverage rate according to the maximum shot quantity and the pit diameter under the maximum shot speed, wherein the diameter and the flow rate of the shots are constant.
2. The method for determining parameters of a thin-walled vane peening process based on damage control of claim 1, wherein establishing a single shot finite element model of an intake side, a vane body and an exhaust side of the thin-walled vane comprises:
establishing a single shot geometric model of an air inlet side, a blade body and an air outlet side according to a thin-wall blade structure based on a real proportion;
Giving density, elastic modulus and poisson ratio to the single-shot geometric model of the air inlet side, the blade body and the air outlet side to obtain the single-shot elastic geometric model of the air inlet side, the blade body and the air outlet side;
Setting Johnson-Cook constitutive parameters and Johnson-Cook damage parameters for the single-shot elastic geometric model of the air inlet side, the blade body and the air outlet side;
Setting pellet parameters, contact properties and boundary conditions for the single pellet elastic geometric model of the air inlet side, the blade body and the air outlet side;
And carrying out grid division on the single-pellet elastic geometric models of the air inlet side, the blade body and the air outlet side by adopting different unit types to obtain single-pellet finite element models of the air inlet side, the blade body and the air outlet side.
3. The method for determining the parameters of the shot peening process of the thin-walled blade based on the damage control according to claim 2, wherein after the same shots collide with the air inlet side, the blade body or the air outlet side corresponding to each single shot finite element model at the same speed, the structure corresponding to the single shot finite element model with the plastic deformation degree is the structure of the thin-walled blade which is most easily damaged.
4. A method for determining parameters of a thin-wall blade peening process based on damage control according to claim 3, wherein a multi-shot random peening finite element model is built in the blade body region of the thin-wall blade, a block region is selected as a target region in the blade body region of the thin-wall blade, parameter setting and mesh division are performed in the target region, a plurality of identical shots are randomly generated in the selected target region, and the speed of each shot is given to be the maximum shot speed.
5. The method for determining parameters of a thin-walled blade peening process based on damage control according to claim 1, wherein the air pressure is calculated by a peening speed empirical formula:
wherein v s is the pellet speed, p is the air pressure, d is the pellet diameter, and q is the flow.
6. The method for determining parameters of a thin-walled vane peening process based on damage control according to claim 1, wherein the coverage rate is calculated by a shot number formula:
Where n is the number of shots, S is the area of the impact area, C (n) is the coverage, and r is the pit radius.
CN202410272422.8A 2024-03-11 2024-03-11 Thin-wall blade shot peening process parameter determination method based on damage control Pending CN118153382A (en)

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