Materials Science and Engineering A 426 (2006) 173180

Finite element modelling of shot peening process:

Prediction of the compressive residual stresses,
the plastic deformations and the surface integrity
M. Frija a , T. Hassine b , R. Fathallah c, , C. Bouraoui b , A. Dogui b ,
Laboratoire de Genie Mecanique
a Institut Superieur des Sciences Appliquees et de Technologie de Sousse, Cite Taffala, 4003 Sousse, Tunisia
b Ecole Nationale dIngenieurs de MonastirAvenue Ibn Jazzar 5019 Monastir, Tunisia
c Ecole Nationale dIngenieurs de Sousse, Cite Taffala, 4003 Sousse, Tunisia

Received 18 November 2005; accepted 30 March 2006

Abstract
This paper presents a numerical simulation of the shot peening process using finite element method. The majority of the controlling parameters
of the process have been taken into account. The shot peening loading has been characterised by using energy equivalence between the dynamic
impact and a static indentation of a peening shot in the treated surface. The behaviour of the subjected material is supposed to be elastic plastic with
damage. An integrated law of the damage proposed by Lematre and Chaboche has been used. The proposed model leads to obtain the residual
stress, the plastic deformation profiles and the surface damage. An application on a shot peened Ni-based super alloy Waspaloy has been carried
out. The comparison of the residual stresses, obtained by X-ray diffraction method and by finite element calculation, shows a good correlation.
The in-depth profile of the plastic deformations and the superficial damage values are in good agreement with the experimental observations.
2006 Elsevier B.V. All rights reserved.

Keywords: Shot peening; Residual stresses; Plastic deformations; Superficial damage; Surface imperfections; Finite element method

1. Introduction
Controlled shot peening is the most widely used method
of pre-stressing mechanical components such as, automobile
leaf springs, aero-engine blades, gears, axle bearings, etc. [1].
It consists of projecting small shots made of steel, ceramic or
glass, at relatively high velocities (20100 m/s) at the surfaces
of the metallic parts. It leads, principally, to induce two favor-
able effects: (i) compressive residual stresses in the near surface
region and (ii) consolidation of the superficial treated layers,
so as to ensure a better resistance to fatigue and stress corro-
sion [25]. However, in many cases, and especially where the
shot peening parameters are not well chosen (large shot, over
peening, high velocities, etc.), there is a risk of deteriorating or
altering the integrity of the treated surface by inducing superfi-
This work is a part of the Phd thesis of Mr. M. Frija supervised by T. Hassine
and R. Fathallah.
Corresponding author. Tel.: +216 98 22 88 69; fax: +216 73 332 658.
E-mail address: raouf.fathallah@issatso.rnu.tn (R. Fathallah).
cial defects such as overlaps, scales, micro cracks and surface
roughness imperfections [69], which can induce significant
decrease of the high cycle fatigue strength of the treated part
[10,11]. In order to predict the high cycle fatigue behavior of
the shot peened part (e.g. by using fatigue criteria), it is nec-
essary to predict completely the initial state of the shot peened
surface conditions [12].
To predict the shot peening induced plastic deformations and
the residual stresses, a theoretical shot peening model, based
on the simplified method of elastic plastic calculations of Zarka
and Casier [13] has been proposed firstly by Guechichi et al.
[14] and improved by M.T. Khabou et al. and R. Fathallah et
al. [15,16], respectively. It has the advantages to take into acco-
unt the majority of the controlling process parameters. However,
it is difficult to identify the coefficients used to model the
elastic-plastic behavior law of the treated material, particularly,
for the cases of non-linear work hardening materials.
Different authors [1719] have developed simple theoret-
ical analysis of the shot peening process. Those analytical
approaches lead principally, to determine the residual stresses

0921-5093/$ see front matter 2006 Elsevier B.V. All rights reserved.
doi:10.1016/j.msea.2006.03.097
174 M. Frija et al. / Materials Science and Engineering A 426 (2006) 173180
and the plastic deformations induced in the first affected layers
of the shot peened part.
Several models are conducted to simulate the shot peen-
ing process by using the finite element method. Some of them
are axi-symmetric and consist to simulate an impact of one
shot [20,21]. Others were developed by using three-dimensional
finite element models in order to be more realistic [2225].
Generally, the shots were supposed to be perfectly rigid. The
subjected material behavior law was supposed, in some cases
elastic plastic, and in other cases rate-sensitive material [26,27].
The majority of the cited shot peening finite element simula-
tions allow predicting the introduced plastic deformations and
residual stresses profiles in the near surface region.
The principal originality of this work is the prediction of
the superficial shot peening damage, characterized by the dam-
age variable D, proposed by Lematre and Chaboche [28]. The
damage has been supposed isotropic (does not depend on the
direction). The damage has been determined by using an inte-
grated law, depending on the accumulated plastic deformation.
This model permits, also, to predict and to characterize the shot
peening surface geometrical irregularities.
2. Mechanics of shot peening process
2.1. Impact of two solids
During an impact between two solids, the two following
energy transformation steps can be distinguished: (i) the phase
of deformation where the stream kinetic energy is transformed
into potential energy of deformation, and (ii) the phase of shot
restitution. If the impact is completely elastic, the potential
energy is totally transformed into returned kinetic energy and if
the contact is elastic-plastic, the potential energy is only partially
transformed. If there is internal degrees of freedom (tempera-
ture, vibrations, deformations, etc.), a part of the stream kinetic
energy can be transformed into internal energy or an internal
energy can be transformed into kinetic energy.
Let us consider a shot with mass, m, impacting a semi-finite
body at a velocity, Vi , under an angle of impingement, , and
returning at a velocity, Vr , under an angle,  (Fig. 1). The
impact is characterized by a coefficient, er , called the coefficient
of restitution or impact coefficient equals to 1 for an elastic
contact, 0 for a plastic contact and between 0 and 1 for the case
Fig. 1. Energy transmitted during contact shot/material.
of elastic-plastic contact. It is defined by the normal projection
of the stream velocity to the normal projection of the return
velocity ratio.
Vr sin
er = (1)
Vi sin
The coefficient of restitution, er , depends on the conditions of
the contact between the shot and the treated material. It depends
essentially on the shot/material hardness ratio.
2.2. Calculation of energy stored by plastic deformation in
the peened material
During the impact, the movement of the shot can be a slid-
ing, an in depth penetration, a spin, or a combination of these
motions. In order to simplify the present study, the following
assumptions have been taken into account: (i) the movement of
the shot particles is supposed to be an in depth penetration and
the surface sliding was supposed to be negligible and (ii) the
dynamic impact of the peening shot is supposed to be equiva-
lent to a static indentation. The energy restored in the plasticized
first outer layers by the static indentation is equal to that restored
by the dynamic impact.
For the case of normal impact, the difference between the
initial and the restored kinetic energies is given by the following
expression [16]:
1
W(=90 ) = mVi2 (1 e2r ) (2)
2
In our case, we assume that the shot is perfectly rigid, and it
cannot store plastic deformation. The difference between the
two kinetic energies W(=90 ) is composed of the energy
needed to plastify the shot peened surface layers Wp and the
dissipated energy during the impact (by vibrations, superficial
heating, etc.) Wd :
W(=90 ) = Wp + Wd (3)
The energy dissipated during impact is not exactly determined.
W. Johnson [29] introduces an efficiency coefficient K, defined
as the energy transmitted to the treated material to the supplied
total initial energy ratio. It is estimated to be 0.80.9 for
mechanical impacts. Then, the energy transmitted by plastic
deformation to the treated material can be expressed as follows:
1
Wp = K W = mVi2 (1 e2r )K (4)
2
3. Finite elements simulation of the shot peening process
3.1. Assumptions
The principal assumptions employed in the implementation
of the finite elements model are:
(i) The shot particles are considered rigid spheres of uniform
radius.
(ii) The diameter of the shot taken into account is the nomi-
nal diameter conventionally defined by the SAE J444 [30]
 M. Frija et al. / Materials Science and Engineering A 426 (2006) 173180
Table 1
Table of the size distribution of the cast steel shots granulometry (S230)
Number of standard SAE J 444 Nominal dimension of the grains
S230 0.6 mm
standard. It corresponds to the diameter of the sieve having
a rate of 85% cumulated shots (Table 1). For example, in the
case of the S230 shot, 75% of the diameters are randomly
distributed between 0.6 and 0.84 mm. It is worth noticing,
that the stream kinetic energy is qualified experimentally
by the Almen arc height [31]. The calculation using 0.6 or
0.84 mm diameter will involve a slight change of the veloc-
ity. However, according to the Eq. (2), the stream kinetic
energy is the same in the both cases.
(iii) The area density of impacts is considered uniform. The
residual stress profile is obtained by taking the residual
stresses values from the in-depth nodes located on the
central axis of the damped zone. We suppose that it is
representative of a shot-peening with 100% coverage. The
calculation should be repeated for the case of high harden-
ing materials, which are sensitive to peening coverage [32].
(iv) In our approach, shot peening is considered as a cold
hardening surface treatment. We assume that the mechan-
ical response of the processed material conforms to
elastic-plastic behaviour coupled with damage and the
treated material is not strain rate sensitive.
(v) The velocity of the shot is assumed to be constant during
the impact. Its value has been determined by using
available curves [32] giving the Almen arc height [33] with
shot velocity for a specific shot. Those curves are obtained
by numerical simulations predicting the Almen arc height
obtained by the shot peening. The conventionally nom-
inal shots diameter defined by the SAE J444 standard
[30] is used in the calculation. They are experimentally
calibrated [32].
Fig. 2. Finite element model.
175
Rate cumulated on sieve no. ASTM Opening sieves ISO 565 (mm)
All pass with no. 18 1.00
10% max on no. 20 0.84
85% min on no. 30 0.59
97% min on no. 35 0.5
(vi) The shot is supposed impinging the target surface at
normal incidence = 90 .
3.2. Finite elements model
The simulation has been carried out by using a three-
dimensional finite element elastic plastic model. The analysis
was performed by the commercial finite element code ABAQUS
[34]. In this work, a static analysis has been adopted using an
energy equivalences, in order to simplify the application of the
coupled elastic-plastic damage analysis. Also, it is worth notic-
ing that the dynamic analysis needs an important computing time
and leads, generally, to obtain instable results.
In order to take into account the effect of simultaneous
impacts and the effect of the elongation of the first affected lay-
ers [18], the geometry of the part has been reduced on one cell
with 1 mm width, 1 mm length and 5 mm height dimensions. To
have semi-infinite solid condition suitable to the Hertz solution,
a geometrical sensitivity study has been carried out to optimise
the 5 mm thickness of the target part.
Particular boundary conditions using four symmetry planes
applied on the vertical faces of the target has been considered
(Fig. 2). The cell was meshed by means of eight-node brick
solid elements. In order to improve the accuracy of FE solu-
tions, the contact region was refined with small elements of
0.01 mm 0.01 mm 0.01 mm.
A sensitivity study has been carried out to optimize the dimen-
sions of the element in refined zone, by comparison of the
analytical solutions of the elastic Hertz contact problem [29]
to those obtained by numerical resolution. The shot is modeled
176 M. Frija et al. / Materials Science and Engineering A 426 (2006) 173180

n , the value of the damage D(M, n ) is defined as:

S0
D(M, n ) = (5)
S
where S is the area of the intersection of the plane with the
representative volume element, and S0 the effective area of the
intersections of all micro-cracks or micro-cavities, which lie
within S.

3.3.2. The integrated model

Fig. 3. Definition of Lematre and Chaboche damage variable.
as a rigid sphere and defined by a reference point corresponding
to its center.
3.3. Material behaviour law
3.3.1. Damage modelling
The shape and the size of the shot peening defects can be
considered as discontinuities of the material at the first affected
layer [12]. In this approach, the damage variable D, proposed
by Lematre and Chaboche [28], is used to take into account this
effect. For a representative volume element of a damaged body
at a point M (Fig. 3), oriented by a plane defined by its normal
The treated surface material behaviour law is considered to
be elastic plastic with isotropic hardening. The viscosity of the
treated material under the impact is supposed to be negligible.
We assume that the shot size is not important by comparison to
the treated part, so the heating should be principally located in
the projected shot and in the extremely first outer layer of the
affected surface. In order to predict the shot peening superficial
damage, a Lematre and Chaboche [28] three-dimensional duc-
tile plastic model of damage has been used in its integrated form.
It is expressed as follows:

    
Dc 2 H 2
D= p (1 + )+3(12) D (6)
R D 3 eq
where is the Poissons ratio, H the hydrostatic stress of the
applied stress tensor and eq the Von Mises equivalent stress.
The three variables Dc , R and D are considered constants,

Fig. 4. Flow chart of the calculation.

 M. Frija et al. / Materials Science and Engineering A 426 (2006) 173180 177

Fig. 5. The used stressplastic strain curve for the finite elements calculations.

where D is the initial critical deformation for damage and R
the deformation at rupture for witch the damage D is equal to its
critical value Dc .
p is the cumulated plastic strain defined by the following
expression:
  1/2
2 P P
p= : dt
3 tation (Section 2), which is obtained by imposing depth pene-
where P is the rate of plastic strain.
In our study, the shot peening simulation is reported to a
serial of indentation. The damage parameter is evaluated from
the degree of cumulus of plastic strain.
The elastic plastic calculation was made incrementally by
using the Von Mises criterion. After each increment, the damage
variable D is determined, and the Youngs modulus E in the
elastic law is updated as follows:
Fig. 6. The calculated and the X-ray residual stresses profiles in depth of the
shot peened Waspaloy.
3.4. Shot peening loading
In this work, we use a shot peening equivalent static inden-
(7)
tration of the rigid shot into the treated surface. The imposed
penetration depth is calibrated incrementally by comparison of
the stored energies determined by the finite elements calculation
in the case of static indentation and that calculated by Eq. (2)
in the case of dynamic impact. The friction between the shot
and the treated surface has been characterized by the Coulomb
friction model:
Ff = Fn (9)

Et+t = Et (1 Dt ) (8) where Ff is the friction force, Fn the normal force and the
friction coefficient.
where Et+t is the youngs modulus at the instant t + t and Et
The coefficient of restitution er , the value of the contact effi-
and Dt are respectively the Youngs modulus and the damage
ciency K and the friction coefficient , which are difficult to
value at the instant t.
identify experimentally, are determined by calibration of the
The principal steps of the calculations are presented in flow
finite elements calculated and the X-ray diffraction analysed
chart of Fig. 4. This model is implemented in a subroutine
residual stress profiles.
UMAT in the finite element code ABAQUS [34].

Table 2
Damage parameters
Damage parameters Values

R 0.6
D 0.02
Dc 0.8

Table 3
Shot peening conditions
Almen Shot type Coverage Angle of Friction
intensity A % impingement ( ) coefficient

8A S230 100 90 0.01 and 0.2

Fig. 7. Von Mises equivalent plastic strain profiles vs. depth.
178 M. Frija et al. / Materials Science and Engineering A 426 (2006) 173180

4. Application
The treated part is made of an aeronautical-based
Nickel super-alloy material, Waspaloy (based on Ni0.04C
19.55Cr 1.37Al 2.95Ti 13.51Co4.25Mo0.0063B0.06Zr
(wt.%)). It is well used to resist to high temperature, so its strain
rate sensitivity is supposed to be negligible in this work. The
mechanical properties of the material are: the initial Youngs
modulus E = 210,000 MPa, the Poissons ratio v = 0.3, the
yield stress at 0.2% is 1000 MPa, the ultimate tensile strength
is 1275 MPa, the total elongation at rupture is 25%, and the
hardness is 50 HRC [32].
The plastic material behaviour law was determined by using
the Holloman law [35]:
= A np (10)
where A and n are two material constants, identified by using
the initial and ultimate stress strain values. Fig. 5 shows the
stress plastic strain curve with coefficients A = 1367.11 MPa and
n = 0.05. The supposed damage parameters used in this appli-

Fig. 8. The obtained superficial finite elements damage iso-values under a shot peening indentation: (a) = 0.01 and (b) = 0.2.
 M. Frija et al. / Materials Science and Engineering A 426 (2006) 173180
cation are presented in Table 2. The shot peening conditions
are presented in Table 3. To determine the shot velocity, we use
available curves, giving the Almen arc height versus velocity
for the S230 shot [32]. This abacus is determined by numerical
calculations, where the 0.6 mm conventionally normal diam-
eter is used. The Waspaloy is considered to be not sensitive
to the coverage [32]. So in this modelling, we proceed by none
repeated simultaneous calculations.
5. Results
Fig. 6 shows the residual stress profiles obtained by calcu-
lation and X-ray diffraction technique. A good correlation is
observed between the calculated finite elements and the anal-
ysed residual stresses.
The calibrated model corresponds to the values of K(1
e2r ) = 0.2 and = 0.01. The value of er is estimated equal to
0.86 when K = 0.8 and equal to 0.88 when K = 0.9. These values
are physically coherent for the Ni base super-alloy Waspaloy
case, which is a very hard material.
The calculated in-depth plastic deformations profile induced
by shot peening is presented in Fig. 7. It shows a qualitative
Fig. 9. Change of the maximal value of the superficial damage with the friction
coefficient ().
Fig. 10. Change of the surface residual stress with the friction coefficient ().
179
Fig. 11. Comparison of the residual stress profiles obtained with and without
damage model.
agreement with the full width at half maximum (FWHM) of the
X-ray diffraction peak profile [32].
Fig. 8 presents the iso-values of the calculated superficial
damage D. The obtained maximum values, Dmax are 0.24 for
the friction coefficient = 0.01 and 0.44 for = 0.2. This is in
good agreement with the previous works of [11,12].
Fig. 9 shows the change of the maximum surface damage
value Dmax with the friction coefficient, and Fig. 10 shows the
change of the surface residual stress with the friction coefficient.
In order to support the principal originality of this paper and
to study the influence of the proposed damage model on the
obtained residual stress profiles, a supplementary calculation has
been made by elastic-plastic model without damage. The com-
parison of the obtained residual stresses is reported in Fig. 11.
6. Discussion
The calculated results show the feasibility of the proposed
shot peening finite elements simulations. The obtained shot
peening residual stress and plastic deformation profiles, by
finite elements are in good agreement with the X-ray diffraction
analysed profiles. The proposed model has a complementary
advantage to evaluate the superficial damage values. This is very
interesting to predict correctly the high cycle fatigue resistance
of the shot peened part, as proposed in the works of [11,12],
which take into account the following initial shot peened surface
properties: (i) the compressive residual stress profile, (ii) the
plastic deformation profile and (iii) the superficial damage.
The obtained values of the maximum surface damage are situ-
ated in the border of the shot indentation zone. This is physically
coherent with the previous observations made by Fathallah et al.
[6]. Fig. 12 shows a cross section of the iso-damage values. The
maximum damage values show that the superficial shot peening
cracks will have most probably moustache shape as observed
previously [11,12,36]. Fig. 9 shows that the Dmax value and the
extremely damaged zone increase as the coefficient of friction
increases.
Fig. 10 shows that the amplitude of the surface compressive
residual stress decreases when the friction coefficient increases.
It reaches a slight positive value for the case of friction coefficient
180 M. Frija et al. / Materials Science and Engineering A 426 (2006) 173180
Fig. 12. Cross section of the iso-damage values (case: S230, V = 52 m/s, coverage 100%, friction coefficient = 0.2).
equal to 0.3. This is in agreement with the model proposed by
Fathallah et al. [16].
The comparison of the residual stress profiles obtained with
and without damage is physically coherent. It shows a slight
residual stress relaxation in the first outer layers of the compres-
sive zone (0.1 mm thick). The maximal residual stress amplitude
decreases from 1378 to 1313 MPa. This is in coherence with the
results obtained on shot peened ductile steel [6].
7. Conclusion
A numerical simulation of the shot peening process using
finite element method is presented. The principal hypotheses
are detailed. The shot is supposed to be a rigid sphere. The
mechanical behaviour of the subjected material is assumed to be
elastic plastic coupled with damage, using an integrated form of
the Lematre and Chaboche model. The shot peening loading is
simulated by a static indentation, obtained by an energically
equivalence with the dynamic impact. The feasibility of the
model has been demonstrated by an application in the case of a
standard shot peening on a Ni base super-alloy Waspaloy. The
obtained results are in a good agreement with the experimen-
tal observations. It leads to predict, in addition to, the induced
residual stress and plastic deformation profiles, the superficial
damage. This work will be very interesting to optimise as cor-
rectly as possible, the shot peening conditions parameters.
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