A comprehensive investigation on the effect of controlling parameters of ultrasonic peening treatment on residual stress and surface roughness: Experiments, numerical simulations and optimization

This paper aims to study the effect of controlling parameters of ultrasonic peening treatment (UPT), including the pin diameter, the vertical velocity of the pin, friction coefficient etc. on the residual stress, PEEQ and surface roughness. A method was promoted to simulate the UPT process using the ability of the ABAQUS scripting interface and transferring results between ABAQUS analyses. The finite element results of the proposed method were consistent with the UPT simulation. Moreover, the finite element results agreed well with experimental measurements of residual stress, surface roughness and surface deformation. The results revealed that increasing the pin diameter, the vertical velocity of the pin and also the number of impingements increased the depth of the compressive residual stress layer. Decreasing the vertical and horizontal velocity of the pin and increasing the pin diameter and the distance between two adjacent impingements resulted in a decline of surface roughness parameters (Ra and Rq). A combination of finite element model and multi-objective optimization technique was implemented to determine the optimum controlling parameters of UPT for reaching the maximum compressive residual stress and the minimum surface roughness. For the optimum proposed controlling UPT parameters, the values of −386 MPa, 16.7 μm and 20.9 μm were obtained for the surface residual stress, Ra and Rq, respectively. •A comprehensive experimental and numerical study on residual stress induced by ultrasonic peening treatment•A new method for simulating ultrasonic peening treatment•How controlling parameters of ultrasonic peening treatment affect the residual stresses and the surface roughness•Experimental measurement including of XRD, SEM and 3D scan•A combination of finite element model and multi-objective optimization technique to optimize controlling parameters