Development and Validation of Velocity-Intensity Correlation for Shot Peening Media Using Shotmeter G3

Author:  Gioacchino Salvagio CPI. – Sonaca Montreal, Khaled Tlili P.Eng, PMP – Sonaca Montreal, Christopher Bousquet-Jetté, M.Sc.A, P.Eng – CTA
Source:  The Shot Peener magazine, Vol 40, Issue 2, Spring 2026
Doc ID:  2026012
Year of Publication:  2026
Abstract:  
INTRODUCTION Repeatable and accurate shot peening results rely on closed-loop monitoring and control of critical process parameters. Fundamentally, the transfer of energy during shot peening can be summarized into a simple equation relating mass of the peening media and velocity of impact (1/2 x mass x velocity2). Assuming that constant mass of peening media particles is maintained using a vibratory classifier and regular inspections, velocity becomes a key factor that will influence the intensity. Therefore, it becomes imperative that we understand the relationship better and possibly arrive at a desired level of predictability. Our research project identified three media sizes/types, S-550, 1/8” steel balls and CCW-28 to study the relationship. This data-driven approach to corelate shot velocity with peening intensity was carried out using a robotic shot peening cell equipped with a Tecnar Shotmeter G3 and Photron FastCam. We derived polynomial and linear regression models to predict intensity from velocity measurements through a custom-developed application. Traditionally, intensity is calculated through a saturation curve that is generated by a minimum of four data points and then verified periodically, pre-process using Almen strips. This introduces delays and increases the possibility of variability. Our project addresses the need for real-time intensity estimation by leveraging velocity measurements from different types of sensors and correlating them to Almen intensity values.