Machine Learning Driven Prediction of Residual Stresses for the Shot Peening Process Using a Finite Element Based Grey-Box Model Approach

Benjamin James Ralph, Karin Hartl, Marcel Sorger, Andreas Schwarz-Gsaxner, Martin Stockinger

Research output: Contribution to journalArticleResearchpeer-review


The shot peening process is a common procedure to enhance fatigue strength on load-bearing components in the metal processing environment. The determination of optimal process parameters is often carried out by costly practical experiments. An efficient method to predict the resulting residual stress profile using different parameters is finite element analysis. However, it is not possible to include all influencing factors of the materials’ physical behavior and the process conditions in a reasonable simulation. Therefore, data-driven models in combination with experimental data tend to generate a significant advantage for the accuracy of the resulting process model. For this reason, this paper describes the development of a grey-box model, using a two-dimensional geometry finite element modeling approach. Based on this model, a Python framework was developed, which is capable of predicting residual stresses for common shot peening scenarios. This white-box-based model serves as an initial state for the machine learning technique introduced in this work. The resulting algorithm is able to add input data from practical residual stress experiments by adapting the initial model, resulting in a steady increase of accuracy. To demonstrate the practical usage, a corresponding Graphical User Interface capable of recommending shot peening parameters based on user-required residual stresses was developed.
Original languageEnglish
Article number2
Pages (from-to)39-59
Number of pages21
JournalJournal of Manufacturing and Materials Processing
Issue number2
Publication statusPublished - 21 Apr 2021

Bibliographical note

Publisher Copyright:
© 2021 by the authors. Licensee MDPI, Basel, Switzerland.


  • Digitalization
  • Finite element analysis
  • Machine learning
  • Python scripting
  • Residual stresses
  • Shot peening
  • Smart factory

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