Simulation of the shot peening for helical gears considering tooth profile characteristics

LIU Yi; MEI Xiangqian; GUO Hui; XIONG Junyang; HOU Shengwen; DONG Fan; LIU Geng

doi:10.16578/j.issn.1004.2539.2026.08.012

Abstract：[Objective]Shot peening can significantly improve the fatigue resistance of gears by introducing residual compressive stress into the gear surface layer.In existing numerical simulations of shot peening,the tooth surface is mostly simplified as a local plane,and the effect of tooth profile curvature is not fully considered.To reveal the influence mechanism of tooth profile curvature on residual stress distribution,a shot peening simulation model of helical gears considering tooth profile characteristics was established,and the distribution law of residual stress at key positions of the tooth surface was investigated.[Methods]Firstly,an explicit dynamic simulation model of shot peening was constructed based on the Johnson-Cook constitutive model with the aid of Abaqus software,and a calculation method for coverage under different incident angles was proposed.The accuracy of the model was verified by comparison with test results from prior studies,providing reliable support for subsequent analysis.Secondly,calculation methods for normal curvature,shot incident angle and velocity at the addendum circle,pitch circle,common tangent line and transition surface center of helical gears were derived,and the tooth profile characteristic parameters of each position were clarified.Then,single shot peening simulation was carried out to analyze the influence law of concave and convex tooth surface curvature on the residual stress field.Finally,multiple sets of secondary shot peening process schemes were designed to explore the regulatory effects of shot diameter and peening velocity on residual stress distribution.[Results]The results show that both the surface residual compressive stress and the maximum residual compressive stress present a decreasing trend during the transition of the tooth surface from concave to convex.The surface residual compressive stress,maximum residual compressive stress and depth of the residual stress layer at the transition surface center all reach the maximum values on the whole tooth surface.Secondary shot peening can effectively increase the maximum residual compressive stress,and increasing the shot incident velocity of secondary shot peening is the core strengthening measure,which can provide reference for the optimization of helical gear shot peening processes.