Design and Developement of Fatigue Life Enhancement CNC Shot Peening Machine

The aim of the project is to Design and Develope  a Fatigue life Enhancement Shot peening Machine with computer numeric control system using new specimen fatigue testing approach.After the development of machine we have proved that shotpeening process increases the fatigue l

Project Title

Design and Developement of Fatigue Life Enhancement CNC Shot Peening Machine

Project Area of Specialization

Mechanical Engineering

Project Summary

The aim of the project is to Design and Develope  a Fatigue life Enhancement Shot peening Machine with computer numeric control system using new specimen fatigue testing approach.After the development of machine we have proved that shotpeening process increases the fatigue life and hardness of shafts. This machine is only applicable for shotpeening of shafts, but with certain iteration we can make it applicable to do shot peening of other components.

First of all we do literature review and find many components under cyclic loading fails inspite of the calculation of parameters such as factor of safety, allowable loadings, stresses etc. Components such as gears, shafts, leaf springs and other rotating components can have cyclic or fatigue type loading so component fails abruptly. than we do research and findout how we can improve this process. Than we do many industrial visits to know how this machine works in real life. After certain research we find out another way of doing shotpeening that is specimen approach method. After that we design the machine in solidworks according to our needs. Than we do Simulations in ansys to check weather this machine is applicable in real life. Their are many electrical systems in this machine for the simulation of those components we use labview software. Than we use use matlab sofware to check weather the indentation and compressive residual stresses are useful for us or not. After getting some results we validate those results with shotpeening results from abaqus. In the second phase we started fabrication of machine. After fabrication we do certain tests on the shot peened components and comeup with the results that shotpeening increases the fatigue life and hardness by 50 percent.

Project Objectives

Objectives:

The main objective of this project is to:

1. Design and Develop a CNC Shot peening machine.
2. Selection of shot balls and peening material.
3. Validate the process of shotpeening by testing hardness and fatigue life of shafts after shotpeening process.

Project Implementation Method

The method of our project implementation is based on the different technical phases of project. On industrial scale, before the start shot peening process .We must have knowedge about the work-piece material, strength of material. According to the strength of material we select the shot peening balls media e.g CW-32 or S.280 stainless steel balls.

Before the start of experiment on workpiece, first we perform experiment on the specimens of the same material and note down the shot peening parameters of machine then compare with  the simulations parameters which we already known from the ABAQUS and ANSYS results.

After all the calculations and simulations we start shot peening on the actual workpiece.

After the shot peening experiment, fatigue testing machine and surface hardness machine is required for the comparison of  experment before and after shot peening.

Summary of Implementation Requirements:

• Selection of Work piece Material
• Selection of Shot Peening Balls 
• Experimetation on the Test Specimen
• ANSYS & ABAQUS Simulations
• Decision of final shot peening parameters
• Implementation of parameters on the actual work piece.
• Fatigue Testing Machine 
• Surface hardness Tesing Machine

Benefits of the Project

Many components under cyclic loading fails inspite of the calculation of parameters such as factor of safety, allowable loadings, stresses etc. Components such as gears, shafts, leaf springs and other rotating components can have cyclic or fatigue type loading so component fails abruptly. According to the statistics, over 90% of mechanical failures are caused because of fatigue loading. Since the motion of the engineering products is maintained by the automatic systems (car engines, turbo engines, etc.), the repeated loads on the mechanical parts are inevitable. Hence, if the body of the engineering product contains surface discontinuities or stress concentrating points (sharp edges etc.), failure of the metal body is inevitable too. The fatigue life cycles play an important role in any industry to calculate the life of any component, so that we can replace the component before the failure point.

After this project we will able to enhance the fatigue life and hardness of shafts. Due to which we will be able to use for longer period of time.

Technical Details of Final Deliverable

Design of Machine:

Mechanical assemblies and sub-assemblies of machine is listed below;

1. Rectangular Main Frame
2. Acme-Screw Axis System
3. Boron Carbide Nozzle
4. Assembly of Rotating Chuck
5. Reservoir for the Shot Peening Balls
6. Shot Peening Balls CW-32 and S-280

Working of Machine:

The technical working of CNC Shot Peening Machine is based on three parameters,

1. Rotation of workpiece
2. Velocity of shot peening balls
3. Distance between nozzle and work-piece

Technical Detail:

Technical detail of machine components is listed below;

1. We have  control the rpm's of work piece with the help of motor by regulating the voltage using dimmer.
2. We have designed the machine bed in such a way that both rotating table as well as chuck are mounted on it.
3. Stepper Motors are used for the axis movement 
4. Software Based system in which micro-controllers are used for the operating of machine equipments
5. We have designed the shot peening adapter assembly.
6.  we have designed a shot peening reservoir for the balls which is operated through the compressor and connected with the shot peening nozzle.

Final Deliverable of the Project

Hardware System

Core Industry

Manufacturing

Other Industries

Core Technology

Others

Other Technologies

Sustainable Development Goals

Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Responsible Consumption and Production

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com