Synchronous impact strengthening and stress detection integrated device and method

Abstract

The invention relates to a synchronous impact strengthening and stress detection integrated device and method, and the device comprises a laser device which is used for generating an original laser beam; the light splitting unit is arranged on a light emitting path of the laser and used for splitting the original laser beam into a main light beam and a detection light beam, and the energy proportion of the main light beam is larger than that of the detection light beam; the shock peening unit is arranged on a light emitting path of the main light beam and is used for guiding the main light beam to a to-be-peened area of a workpiece for laser shock peening; the stress detection unit is arranged on a light emitting path of the detection light beam and used for guiding the detection light beam to a detection area of a workpiece for stress detection. The problems that the workpiece laser shock peening efficiency is low, the process is out of control and quality control is disjointed are solved.

Description

Technical Field

[0001] This invention relates to the field of laser shock peening technology, and more specifically, to an integrated device and method for simultaneous shock peening and stress detection. Background Technology

[0002] Laser shock peening is a surface modification technique that uses high-power pulsed lasers to induce plasma shock waves, introducing residual compressive stress on the surface of metal parts, which can significantly improve the fatigue performance of key components.

[0003] Currently, this technology heavily relies on offline stress detection. However, this "processing-detection" separation model has fundamental flaws: First, process control is compromised: the laser shock strengthening process is a quality "black box" where the effect cannot be perceived in real time. Even slight drifts in process parameters can directly lead to batch-level quality accidents, which can only be discovered afterward, resulting in extremely high risks and costs. Second, quality control is disconnected: delayed detection results cannot be used for real-time correction during processing, making it difficult to guarantee the consistency and reliability of the strengthening quality, and failing to meet the stringent requirements for precise control of component fatigue life. Third, efficiency bottlenecks: the independent processes fragment the production flow, slowing down the overall cycle time. Therefore, developing an integrated online and in-situ technology is the inevitable direction to overcome the existing bottlenecks. Summary of the Invention

[0004] Based on this, and in response to the above problems, the present invention provides an integrated device and method for simultaneous impact strengthening and stress detection, which realizes the integration of laser impact strengthening and stress detection, and overcomes the problems of low efficiency, process loss of control and disconnection between quality control and workpiece laser impact strengthening.

[0005] To achieve the above objectives, the present invention provides an integrated device for simultaneous impact strengthening and stress detection, comprising: a laser for generating a primary laser beam; a beam splitting unit disposed on the output optical path of the laser for splitting the primary laser beam into a main beam and a detection beam, wherein the energy proportion of the main beam is greater than that of the detection beam; an impact strengthening unit disposed on the output optical path of the main beam for guiding the main beam to the area to be strengthened of the workpiece for laser impact strengthening; and a stress detection unit disposed on the output optical path of the detection beam for guiding the detection beam to the detection area of ​​the workpiece for stress detection.

[0006] In one specific embodiment, a control unit is further included, which is signal-connected to the laser, the impact strengthening unit, and the stress detection unit. The control unit receives real-time detection data from the stress detection unit and compares it with a preset stress threshold. Based on the comparison result, the control unit feeds back at least one of the pulse energy, pulse width, and repetition frequency of the laser, and / or controls the scanning speed and / or path of the impact strengthening unit.

[0007] In one specific embodiment, the impact enhancement unit is provided with a first beam shaping unit, which is used to shape the main beam and change its beam spot from a Gaussian distribution to a flat-top beam spot with a more uniform energy distribution.

[0008] In one specific embodiment, the shape of the light spot after being shaped by the first beam shaping unit is square or rectangular.

[0009] In one specific embodiment, the first beam shaping unit is a diffractive optical element, a microlens array, or a beam homogenizer.

[0010] In one specific embodiment, the impact strengthening unit further includes a scanning galvanometer assembly, and the control unit is signal-connected to the scanning galvanometer assembly to control the scanning path of the main beam on the workpiece surface.

[0011] In one specific embodiment, the stress detection unit is provided with a second beam shaping unit for shaping the detection beam, expanding it and homogenizing it into a uniform detection spot with a size larger than the enhanced spot of the main beam.

[0012] In one specific embodiment, the beam splitting unit is a beam splitter, an optical fiber beam splitter, or a polarizing beam splitter prism, and its beam splitting ratio is adjustable so that the energy ratio of the main beam is 70% to 95% and the energy ratio of the detection beam is 5% to 30%.

[0013] In one specific embodiment, the stress detection unit is a laser speckle-based stress detection system, including an image sensor. The detection beam irradiates the detection area to form a speckle image. The image sensor acquires the speckle image and transmits it to a control unit. The control unit analyzes the changes in the speckle image to calculate the stress distribution on the workpiece surface. Alternatively, the stress detection unit is a laser-excited X-ray stress analyzer, including an X-ray generating target. The detection beam is guided to the X-ray generating target to excite and generate X-rays. An X-ray detector is used to receive the X-ray signals diffracted from the detection area of ​​the workpiece and transmit them to the control unit. The control unit analyzes the diffracted X-ray signals to calculate the stress distribution on the workpiece surface.

[0014] In one specific embodiment, the device further includes a beam combining unit, which is disposed at the intersection of the final light output paths of the impact strengthening unit and the stress detection unit, for combining the main beam and the detection beam and applying them together to the surface of the workpiece.

[0015] In one specific embodiment, a method for simultaneous impact strengthening and stress detection is also provided, using the aforementioned integrated device for simultaneous impact strengthening and stress detection, comprising the following steps: S1: activating the laser to generate a raw laser beam; S2: splitting the raw laser beam by a beam splitting unit to form a main beam and a detection beam with different energy ratios; S3: guiding the main beam by the impact strengthening unit, and applying it to the area of ​​the workpiece to be strengthened for impact strengthening; S4: simultaneously, guiding the detection beam by the stress detection unit, and applying it to the detection area of ​​the workpiece to collect stress-related signals; repeating steps S2 to S4 until the processing and detection of the entire target area of ​​the workpiece are completed.

[0016] In one specific embodiment, the method further includes the following steps: a control unit connected to the laser, the impact strengthening unit, and the stress detection unit; the stress detection unit transmitting real-time detection data to the control unit; and the control unit adjusting at least one of the pulse energy, pulse width, and repetition frequency of the laser, and / or adjusting the scanning speed and path of the impact strengthening unit in real time, based on the comparison result of the monitoring data and a preset stress threshold.

[0017] Compared with the prior art, the beneficial effects of the present invention are: This invention provides an integrated device and method for simultaneous impact strengthening and stress detection. By using a beam splitter, the energy of a single laser beam is distributed. The higher-energy main beam performs the impact strengthening function, while the lower-energy detection beam performs the stress detection function. This achieves on-demand energy distribution and functional separation, integrating two independent processes into the same equipment and completing them simultaneously. This eliminates workpiece handling time, directly overcomes the "efficiency bottleneck," provides a foundation for real-time quality control, prevents batch quality accidents, ensures quality consistency and reliability, and completely solves the problems of "process out of control" and "quality control disconnect" in existing technologies. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the integrated device for synchronous impact strengthening and stress detection according to the present invention.

[0019] Figure 2 This is a schematic flowchart of a synchronous impact strengthening and stress detection method according to the present invention. Detailed Implementation

[0020] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0021] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0022] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0023] like Figure 1 As shown, this embodiment provides an integrated device for simultaneous impact strengthening and stress detection, including: a laser 10 for generating a primary laser beam; a beam splitting unit 20 disposed on the output optical path of the laser 10 for splitting the primary laser beam into a main beam and a detection beam, wherein the energy proportion of the main beam is greater than that of the detection beam; an impact strengthening unit 30 disposed on the output optical path of the main beam for guiding the main beam to the area to be strengthened of the workpiece 100 for laser impact strengthening; and a stress detection unit 40 disposed on the output optical path of the detection beam for guiding the detection beam to the detection area of ​​the workpiece 100 for stress detection. The present embodiment provides an integrated device for simultaneous impact strengthening and stress detection. Through a beam splitting unit, the energy of a single laser beam is distributed. The higher-energy main beam performs the impact strengthening function, while the lower-energy detection beam performs the stress detection function. This achieves on-demand energy distribution and functional separation, integrating two independent processes into the same device and completing them simultaneously. This eliminates workpiece handling time, directly overcomes the "efficiency bottleneck," provides a foundation for real-time quality control, prevents batch quality accidents, achieves precise control of workpiece fatigue life, ensures quality consistency and reliability, and completely solves the problems of "process out of control" and "quality control disconnect" in existing technologies.

[0024] In one specific embodiment, a control unit 50 is also included, which is signal-connected to the laser 10, the shock strengthening unit 30, and the stress detection unit 40. This control unit receives real-time detection data from the stress detection unit 40 and compares it with a preset stress threshold. Based on the comparison result, it feeds back and controls at least one of the pulse energy, pulse width, and repetition frequency of the laser 10, and / or controls the scanning speed and / or path of the shock strengthening unit 30. The control unit 50 receives real-time detection data, compares it with the preset stress threshold, and dynamically adjusts the parameters of the laser or the shock strengthening unit, forming a closed loop of "perception-decision-execution." This transforms the laser shock strengthening process from an "open-loop black box" to a "closed-loop transparent system," enabling real-time correction of process drift and ensuring consistent and reliable quality.

[0025] In one specific embodiment, the impact strengthening unit 30 is provided with a first beam shaping unit 301, which is used to shape the main beam, transforming its beam spot from a Gaussian distribution into a flat-top beam spot with a more uniform energy distribution. Exemplarily, the beam spot shaped by the first beam shaping unit 301 is square or rectangular. Exemplarily, the first beam shaping unit 301 is a diffractive optical element, a microlens array, or a beam homogenizer. Using diffractive optical elements, microlens arrays, or beam homogenizers, the laser energy is shaped from a Gaussian distribution with a high center and low edges into a flat-top beam spot or a regular-shaped beam spot with uniform energy distribution. This solves the problem of uneven strengthening caused by traditional Gaussian beam spots. The flat-top beam spot can introduce uniform residual compressive stress during single-point impact; the square / rectangular beam spot can achieve seamless and uniform coverage during scanning overlap, avoiding stress fluctuations and significantly improving the quality consistency of the strengthening layer, thereby reliably extending the life of the component.

[0026] In one specific embodiment, the impact strengthening unit 30 further includes a scanning galvanometer assembly 302. The control unit 50 is signal-connected to the scanning galvanometer assembly 302 and is used to control the scanning path of the main beam on the surface of the workpiece 100. This achieves highly efficient and flexible automated processing, which is particularly suitable for parts with complex shapes, such as aero-engine blades, and complements the high efficiency of the integrated device.

[0027] In one specific embodiment, the stress detection unit 40 is provided with a second beam shaping unit for shaping the detection beam, expanding and homogenizing it into a uniform detection spot larger than the enhanced spot of the main beam, so as to cover the detection area. The second beam shaping unit includes a beam expander 401 and a homogenizing element 402 disposed thereafter. The homogenizing element 402 is an integrating bar, a lens array, or a microlens array, used to expand and homogenize the detection beam into a larger, uniformly energetic spot, expanding the sampling area of ​​stress detection from a "point" to a "surface". This obtains regional average stress information, and the results are more representative and better reflect the overall stress state of the enhanced area, avoiding the random errors of single-point detection, and making the data fed back to the control unit 50 more stable and reliable.

[0028] In one specific embodiment, the beam splitting unit 20 is a beam splitter, fiber optic beam splitter, or polarizing beam splitter prism, and its beam splitting ratio is adjustable, so that the energy ratio of the main beam is 70%~95% and the energy ratio of the detection beam is 5%~30%. According to the material and process requirements, the energy ratio of the main beam and the detection beam is precisely allocated to ensure that both can work in the optimal energy range, providing process flexibility and optimization capabilities. It can ensure that the laser shock strengthening has sufficient energy density to produce effective plastic deformation, and ensure that the detection beam has sufficient signal-to-noise ratio for accurate measurement. This makes the integrated device for synchronous shock strengthening and stress detection provided in this embodiment adaptable to the processing needs of various materials and has strong application scalability.

[0029] In one specific embodiment, the stress detection unit 40 is a laser speckle-based stress detection system, including an image sensor 403. The detection beam irradiates the detection area to form a speckle image. The image sensor acquires the speckle image and transmits it to a control unit 50. The control unit 50 analyzes the changes in the speckle image to calculate the stress distribution on the surface of the workpiece 100. Alternatively, the stress detection unit 40 is a laser-excited X-ray stress analyzer, which includes an X-ray generating target (not shown in the figure). The detection beam is guided to the X-ray generating target to excite and generate X-rays. An X-ray detector (not shown in the figure) is used to receive the X-ray signals diffracted from the detection area of ​​the workpiece 100 and transmit them to the control unit 50. The control unit 50 analyzes the diffracted X-ray signals to calculate the stress distribution on the surface of the workpiece 100.

[0030] Understandably, in the present invention, a device for simultaneous impact strengthening and stress detection is provided, wherein the detection area is the same as the area to be strengthened; or the detection area is a different area from the area to be strengthened, wherein the detection area is a region located adjacent to the area to be strengthened and affected by its stress field.

[0031] In one specific embodiment, the integrated device for synchronous impact strengthening and stress detection further includes a beam combining unit 60. The beam combining unit 60 is located at the intersection of the final light output paths of the impact strengthening unit 30 and the stress detection unit 40. It is used to combine the main beam and the detection beam and apply them together to the surface of the workpiece 100. This allows for direct detection of the immediate effect of the impact point, enabling more comprehensive quality monitoring. The beam combining design ensures that processing and detection target the same location, achieving "in-situ" detection. In-situ detection data feedback is the most direct and accurate.

[0032] like Figure 2 As shown, in one specific embodiment, a method for simultaneous impact strengthening and stress detection is also provided. Using the aforementioned integrated device for simultaneous impact strengthening and stress detection, the method includes the following steps: S1: Activating the laser to generate a raw laser beam; S2: Splitting the raw laser beam by a beam splitting unit to form a main beam and a detection beam with different energy ratios; S3: After being guided by the impact strengthening unit, the main beam acts on the area to be strengthened of the workpiece for laser impact strengthening; S4: Simultaneously, after being guided by the stress detection unit, the detection beam acts on the detection area of ​​the workpiece to collect stress-related signals; Repeating steps S2 to S4 until the processing and detection of the entire target area of ​​the workpiece are completed.

[0033] In one specific embodiment, in step S4, the stress detection unit is a laser speckle-based stress detection system, including an image sensor. The detection beam irradiates the detection area to form a speckle image. The image sensor acquires the speckle image and transmits it to the control unit. The control unit analyzes the changes in the speckle image to calculate the stress distribution on the workpiece surface. Alternatively, the stress detection unit is a laser-excited X-ray stress analyzer, which includes an X-ray generating target. The detection beam is guided to the X-ray generating target to excite and generate X-rays. An X-ray detector is used to receive the X-ray signals diffracted from the detection area of ​​the workpiece and transmit them to the control unit. The control unit analyzes the diffracted X-ray signals to calculate the stress distribution on the workpiece surface.

[0034] In one specific embodiment, the method further includes the following steps: a control unit connected to the laser, the impact strengthening unit, and the stress detection unit; the stress detection unit transmitting real-time detection data to the control unit; and the control unit adjusting at least one of the pulse energy, pulse width, and repetition frequency of the laser, and / or adjusting the scanning speed and / or path of the impact strengthening unit in real time, based on a comparison between the monitoring data and a preset stress threshold.

[0035] In one specific embodiment, in step S3, before the main beam acts on the workpiece, it is first shaped by the first beam shaping unit to form a flat-topped light spot or a regular-shaped light spot. Understandably, the regular-shaped light spot is a square or rectangular light spot.

[0036] In one specific embodiment, in step S4, before the detection beam acts on the workpiece, it is first shaped by a second beam shaping unit to form a large-sized uniform detection spot.

[0037] In one specific embodiment, the material of the workpiece is titanium alloy, aluminum alloy, high-strength steel, or high-temperature alloy.

[0038] In one specific embodiment, the synchronous impact strengthening and stress detection method can be used to improve the fatigue life and stress corrosion resistance of key components of aero-engine blades and aircraft structures.

[0039] It should be noted that, for those skilled in the art, it is obvious that the present invention is not limited to the details of the above exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention, and no reference numerals in the claims should be construed as limiting the scope of the claims.

[0040] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A device integrating synchronous impact strengthening and stress detection, characterized in that: include: Laser, used to generate a raw laser beam; A beam splitting unit is disposed in the output optical path of the laser and is used to split the original laser beam into a main beam and a detection beam, wherein the energy proportion of the main beam is greater than the energy proportion of the detection beam. An impact strengthening unit, disposed in the output optical path of the main beam, is used to guide the main beam to the area of ​​the workpiece to be strengthened for laser impact strengthening; and, A stress detection unit is disposed on the light output path of the detection beam and is used to guide the detection beam to the detection area of ​​the workpiece for stress detection.

2. The integrated device for synchronous impact strengthening and stress detection according to claim 1, characterized in that: It also includes a control unit, which is signal-connected to the laser, the impact strengthening unit and the stress detection unit, for receiving real-time detection data from the stress detection unit and comparing it with a preset stress threshold, and for feeding back control of at least one of the pulse energy, pulse width and repetition frequency of the laser based on the comparison result, and / or controlling the scanning speed and / or path of the impact strengthening unit.

3. The integrated device for synchronous impact strengthening and stress detection according to claim 1, characterized in that: The impact strengthening unit is provided with a first beam shaping unit, which is used to shape the main beam, transforming its beam spot from a Gaussian distribution to a flat-top beam spot with a more uniform energy distribution.

4. The integrated device for synchronous impact strengthening and stress detection according to claim 3, characterized in that: The shape of the light spot after shaping by the first beam shaping unit is square or rectangular.

5. The integrated device for synchronous impact strengthening and stress detection according to claim 3 or 4, characterized in that: The first beam shaping unit is a diffractive optical element, a microlens array, or a beam homogenizer.

6. The integrated device for synchronous impact strengthening and stress detection according to claim 2, characterized in that: The impact strengthening unit also includes a scanning galvanometer assembly. The control unit is signal-connected to the scanning galvanometer assembly and is used to control the scanning path of the main beam on the workpiece surface.

7. The integrated device for synchronous impact strengthening and stress detection according to claim 1, characterized in that: The stress detection unit is provided with a second beam shaping unit, which is used to shape the detection beam, expand it and homogenize it into a uniform detection beam with a size larger than the enhanced beam spot of the main beam.

8. The integrated device for synchronous impact strengthening and stress detection according to claim 1, characterized in that: The beam splitting unit is a beam splitter, fiber optic beam splitter, or polarizing beam splitter prism, and its beam splitting ratio is adjustable so that the energy ratio of the main beam is 70% to 95% and the energy ratio of the detection beam is 5% to 30%.

9. The integrated device for synchronous impact strengthening and stress detection according to claim 2, characterized in that: The stress detection unit is a laser speckle-based stress detection system, including an image sensor. The detection beam irradiates the detection area to form a speckle image. The image sensor acquires the speckle image and transmits it to the control unit. The control unit analyzes the changes in the speckle image to calculate the stress distribution on the workpiece surface. Alternatively, the stress detection unit is a laser-excited X-ray stress analyzer, which includes an X-ray generating target. The detection beam is guided to the X-ray generating target to excite and generate X-rays. An X-ray detector is used to receive X-ray signals diffracted from the detection area of ​​the workpiece and transmit them to a control unit, which analyzes the diffracted X-ray signals to calculate the stress distribution on the surface of the workpiece.

10. The integrated device for synchronous impact strengthening and stress detection according to claim 1, characterized in that: The device also includes a beam combining unit, which is located at the intersection of the final light output paths of the impact strengthening unit and the stress detection unit, and is used to combine the main beam and the detection beam and apply them together to the surface of the workpiece.

11. A method for synchronous impact strengthening and stress detection, characterized in that: Using the integrated device for synchronous impact strengthening and stress detection according to any one of claims 1-10, the method includes the following steps: S1: Start the laser to generate the original laser beam; S2: The original laser beam is split by the beam splitting unit to form a main beam and a detection beam with different energy ratios; S3: After being guided by the impact strengthening unit, the main beam acts on the area of ​​the workpiece to be strengthened for impact strengthening. S4: Simultaneously, the detection beam, guided by the stress detection unit, acts on the detection area of ​​the workpiece to collect stress-related signals; repeat steps S2 to S4 until the processing and detection of the entire target area of ​​the workpiece are completed.

12. The method for synchronous impact strengthening and stress detection according to claim 11, characterized in that: The method also includes the following steps: a control unit connected to the laser, the impact strengthening unit, and the stress detection unit; the stress detection unit transmits real-time detection data to the control unit; and the control unit adjusts at least one of the pulse energy, pulse width, and repetition frequency of the laser in real time, and / or adjusts the scanning speed and path of the impact strengthening unit, based on the comparison between the monitoring data and a preset stress threshold.

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