范俊锴, 刘帅, 赵武.薄橡胶层改善喷丸质量机理研究[J].河南理工大学学报（自然科学版）,2024,43(4):103-110.

FAN J K, LIU S, ZHAO W.Study on mechanism of thin rubber layer in improving shot peening quality[J].Journal of Henan Polytechnic University(Natural Science) ,2024,43(4):103-110.

薄橡胶层改善喷丸质量机理研究

范俊锴, 刘帅, 赵武

河南理工大学 机械与动力工程学院，河南 焦作 454000

摘要: 目的 为了解决喷丸导致的金属表面粗糙度提升问题， 方法 提出在金属表面铺设薄层橡胶层，通过薄橡胶层的变形均匀化丸粒的冲击压力，进而抑制丸粒冲击所造成的粗糙度急剧增加的新工艺。为验证新工艺的可行性并揭示其机理，采用有限元软件Abaqus分别建立传统喷丸、黏结橡胶层喷丸和自由铺设橡胶层喷丸的仿真模型；设定丸粒为半径0.5 mm的球形刚体，丸粒初始速度为50 m/s；工件材料为Q235，采用Johnson-Cook本构模型；薄层橡胶采用双参数Mooney-Rivlin本构模型；仿真模型中不同部件之间的摩擦系数均设定为0.2；所有模型均采用显式求解方法。 结果 在传统喷丸、黏结薄橡胶层喷丸和自由铺设橡胶喷丸条件下，工件表面丸粒冲击点的残余压应力分别为96，343，252 MPa，工件表层最大残余压应力分别为391，426，373 MPa，工件表面的残余压应力得到显著提升；3种喷丸工艺下冲击压痕分别为56.2，26.1，35.4 μm，表面薄层橡胶有效降低了工件表面粗糙度；工件表层残余应力的分布形式与橡胶层的厚度密切相关，当橡胶厚度分别为0.05，0.20 mm时，所得到的最大残余压应力分别为329，373 MPa，距离工件表面分别为256，141 μm。 结论 在机理上，橡胶的大变形特征增大了丸粒的冲击作用面积，延长了冲击作用时间，是薄橡胶层能够改善喷丸质量的根本原因。

关键词:喷丸;薄橡胶;粗糙度;残余压应力;有限元方法

doi:10.16186/j.cnki.1673-9787.2022040037

基金项目:国家自然科学基金资助项目（51405136）；河南省科技攻关项目（212102210004）；河南理工大学青年骨干教师资助计划项目（2020XQG-01）；河南理工大学机械工程重点学科资助项目

收稿日期:2022/04/14

修回日期:2022/09/05

出版日期:2024/07/15

Study on mechanism of thin rubber layer in improving shot peening quality

FAN Junkai, LIU Shuai, ZHAO Wu

School of Mechanical and Power Engineering，Henan Polytechnic University，Jiaozuo 45400，Henan，China

Abstract: Objectives To reduce the surface roughness of metal caused by shot peening，  Methods a novel approach was proposed to apply a thin rubber layer on the metal surface.This process aimed to homogenize the impact pressure of particles through the deformation of the rubber layer，hereby mitigating the increase in roughness resulting from particle impacts.The feasibility and underlying mechanism of this new process were investigated.The simulation models of traditional shot peening，adhesive thin rubber shot peeing，and free laid thin rubber shot peeing were established by the finite element software Abaqus.The particle was modeled as a spherical rigid body with a radius of 0.5 mm and an initial velocity of 50 m/s.The workpiece material was Q235，and the Johnson-Cook constitutive model was adopted.For the thin layer rubber，the two-parameter Mooney-Rivlin constitutive model was employed.The friction coefficient between different components in the simulation model was set to 0.2.All the models were solved by the explicit method.  Results The residual compressive stress at the impact point of particles on the workpiece surface was 96，343，252 MPa under traditional shot peening，adhesive thin rubber shot peeing，and free laid thin rubber shot peeing respectively.Similarly，the maximum residual compressive stress around the workpiece surface was 391，426，373 MPa respectively.There was a significant increase in the residual compressive stress on the workpiece surface with the thin rubber layer.The impact indentations resulting from shot peening processes was 56.2，26.1，35.4 μm，respectively.The application of a thin rubber layer on the workpiece surface effectively mitigated its roughness.The distribution of residual stress on the workpiece surface exhibited a close correlation with the thickness of the employed rubber layer.Specifically，when utilizing rubber layers with 0.05，0.20 mm in thickness，maximum compressive residual stresses of 329，373 MPa respectively at distances of 256，141 μm beneath the workpiece surface were achieved.  Conclusions The large deformation characteristic of rubber enhanced the impact area of particles and extended the duration of impact，thereby serving as the fundamental reason for the improved shot peening quality achieved by a thin rubber layer.

Key words:shot peening;thin rubber layer;roughness;residual compressive stress;finite element method