Multi-field coupling stress regulation system and control method thereof

Abstract

The application discloses a multi-field coupling stress regulation system and a control method thereof, and belongs to the technical field of material processing and residual stress regulation. The system comprises a mechanical vibration internal stress regulation module, an ultrasonic internal stress regulation module, a thermal field internal stress regulation module, an electromagnetic coupling internal stress regulation module, a sensor array module and a control module. The control module is used for cooperating with the mechanical vibration internal stress regulation module, the ultrasonic internal stress regulation module, the thermal field internal stress regulation module and the electromagnetic coupling internal stress regulation module to control output parameters and time sequences of the modules according to a preset multi-field coupling process model and in combination with real-time states of a workpiece and an environment of the workpiece. Multi-field cooperation can shorten a period of traditional heat treatment or cryogenic treatment from several hours or several tens of hours to several tens of minutes to several hours, and can effectively eliminate deep and three-dimensional complex residual stress which is difficult to be treated by traditional methods, and a stress elimination rate can reach 80% to 95%.

Description

Technical Field

[0001] This invention relates to a multi-field coupled stress control system and its control method, specifically to a multi-field coupled stress control system and its control method that integrates mechanical vibration, ultrasound, annealing, cryogenics and electromagnetics. It is mainly used for the elimination and control of residual stress in metal components and belongs to the field of material processing and residual stress control technology. Background Technology

[0002] Residual stress is the internal stress that remains in a self-equilibrium state within a workpiece after processing (such as welding, casting, heat treatment, and cutting) due to uneven plastic deformation, phase transformation, or thermal effects. Excessive tensile residual stress can significantly reduce the fatigue life and stress corrosion resistance of the workpiece, and lead to processing deformation and dimensional instability. Therefore, efficient and precise control of residual stress is one of the key technologies in manufacturing.

[0003] Currently, commonly used residual stress control techniques each have their limitations: Heat treatment (annealing): The most reliable method, but it is energy-intensive, has a long cycle, and is prone to causing oxidation and softening of the workpiece surface. It is also not suitable for large workpieces.

[0004] Mechanical vibration aging: The equipment is portable and has low energy consumption, but it is not effective for high rigidity and thick-walled components, and is easily affected by environmental noise.

[0005] Cryogenic treatment: It can effectively transform residual austenite and improve dimensional stability, but it is usually used alone as a post-treatment and stress relief is not thorough.

[0006] Ultrasonic impact treatment: It can introduce beneficial compressive stress, but the depth of action is shallow, and it is mainly suitable for weld surfaces.

[0007] Electromagnetic field treatment: under certain conditions, it can promote dislocation movement, but its effect is unstable when applied alone.

[0008] Therefore, the single or simple combination of the above methods (such as annealing followed by deep cooling) lacks an integrated system and control method that can organically integrate and synergize multiple energy fields such as mechanical force, heat, cold, electricity, and magnetism in time and space. This results in the inability to fully utilize the synergistic effects between various physical fields (such as the combined effect of thermo-acoustic-electricity promoting dislocation motion, and the combined effect of deep cooling and magnetic fields promoting martensitic phase transformation), thus limiting the efficiency and effectiveness of residual stress control. Summary of the Invention

[0009] To address the aforementioned technical problems, this invention provides a multi-field coupled stress control system and its control method.

[0010] This invention is achieved through the following technical solution: A multi-field coupled stress control system, comprising: Mechanical vibration internal stress control module, used to apply mechanical vibration to the workpiece; An ultrasonic internal stress control module is used to apply ultrasonic vibration or ultrasonic impact to a workpiece. The thermal stress control module is used to adjust the workpiece temperature according to the set temperature curve. Electromagnetic coupling internal stress control module, used to generate a controllable static magnetic field or dynamic magnetic field and / or electric field in the environment of the workpiece; Sensor array module, used to monitor the status of the workpiece and its environment in real time; The control module is electrically connected to the mechanical vibration internal stress control module, the ultrasonic internal stress control module, the thermal field internal stress control module, the electromagnetic coupling internal stress control module, and the sensor array module. It is used to coordinately control the output parameters and timing of the mechanical vibration internal stress control module, the ultrasonic internal stress control module, the thermal field internal stress control module, and the electromagnetic coupling internal stress control module according to a preset multi-field coupling process model and in combination with the real-time state of the workpiece and its environment.

[0011] The mechanical vibration internal stress control module has a vibration frequency of 5Hz~200Hz and an amplitude of 0.1mm~5mm. The ultrasonic internal stress control module operates at a frequency of 15kHz to 60kHz and has an output power of 100W to 5kW.

[0012] The thermal field internal stress control module includes: The annealing heating unit has a heating temperature range of room temperature to 800℃ and a temperature control accuracy of ±1℃. It is used to heat the workpiece according to the set temperature rise curve. The cryogenic cooling unit has a cooling temperature range of -190℃ to -50℃ and a controllable cooling rate, and is used to cool workpieces according to a set cooling curve.

[0013] The electromagnetic coupling internal stress control module can generate a static magnetic field with a strength of 0.1T~5T, an alternating magnetic field with a frequency of 10Hz~1000Hz, and / or a DC electric field or pulsed electric field with a field strength of 0~500V / cm.

[0014] The system also includes a sealable multi-field coupling processing cavity, in which the mechanical vibration internal stress control module, ultrasonic internal stress control module, thermal field internal stress control module, and electromagnetic coupling internal stress control module are all located.

[0015] The system also includes a material carrying module and a material transfer manipulator located in the multi-field coupling processing cavity. The mechanical vibration internal stress control module, the ultrasonic internal stress control module, the thermal field internal stress control module, and the electromagnetic coupling internal stress control module are arranged around the material transfer manipulator. The material transfer manipulator is used to realize the turnover of workpieces between the mechanical vibration internal stress control module, the ultrasonic internal stress control module, the thermal field internal stress control module, and the electromagnetic coupling internal stress control module.

[0016] A control method for a multi-field coupled stress regulation system includes the following steps: Step 1: Place the workpiece to be processed on the material carrying module, and then install the sensor array module on the workpiece and the multi-field coupling processing cavity; Step 2: Input the basic information of the workpiece to be processed, the initial residual stress distribution characteristics, and the target performance requirements into the control module; Step 3: The control module generates and recommends a multi-field coupling processing timing based on its built-in algorithm; Step 4: The control module, based on the multi-field coupling process timing it generates and recommends, coordinates and controls the outputs of the mechanical vibration internal stress control module, ultrasonic internal stress control module, thermal field internal stress control module, and electromagnetic coupling internal stress control module in real time, and performs closed-loop feedback adjustment based on the information collected by the sensor array module. Step 5: After completing the internal stress adjustment of the workpiece, the control module restores the multi-field coupling treatment cavity and the workpiece to a safe temperature according to the set rate, removes all loads, and outputs an internal stress adjustment treatment report.

[0017] The multi-field coupling process sequence in step three includes multiple or all of the following stages: mechanical vibration-dominated stage, ultrasonic vibration or ultrasonic impact-dominated stage, annealing heating or annealing heat preservation stage, electromagnetic assisted vibration stage, cryogenic rapid cooling stage, cryogenic heat preservation and electromagnetic synergy stage, and low temperature recovery stage.

[0018] The multi-field coupling process sequence in step three includes a cryogenic-ultrasonic-electromagnetic synergistic processing process. After the workpiece reaches the cryogenic temperature, ultrasonic vibration and a strong pulsed electromagnetic field are applied simultaneously to promote the transformation of residual austenite and regulate micro-stress. The multi-field coupling process sequence in step three includes a vibration-annealing composite process, in which the workpiece is heated to 200℃~1200℃ and the temperature is kept below the recrystallization temperature of the workpiece. Then, mechanical vibration or ultrasonic vibration is applied to promote dislocation movement and stress homogenization.

[0019] The algorithm built into the control module is either a fuzzy logic algorithm or a neural network algorithm.

[0020] The beneficial effects of this invention are as follows: 1. High efficiency: The synergistic effect of multiple fields can shorten the cycle of traditional heat treatment or cryogenic treatment from several hours or tens of hours to tens of minutes to several hours.

[0021] 2. High efficiency: It can effectively eliminate deep, three-dimensional complex residual stresses that are difficult to handle by traditional methods, with a stress elimination rate of 80% to 95%.

[0022] 3. Low energy consumption and environmental protection: Compared with overall high temperature and long time annealing, the overall energy consumption is reduced by 30% to 60%, and there is no waste gas or wastewater discharge.

[0023] 4. Performance enhancement: While eliminating stress, it can significantly improve the workpiece's hardness, wear resistance, dimensional stability and fatigue life.

[0024] 5. High versatility: Through programmed control, it is applicable to a variety of metal materials (steel, aluminum alloy, titanium alloy, etc.) and workpieces of different sizes and geometries. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the structure of the present invention.

[0026] In the diagram: 1-Mechanical vibration internal stress control module, 2-Ultrasonic internal stress control module, 3-Thermal field internal stress control module, 31-Annealing heating unit, 32-Deep cryogenic cooling unit, 4-Electromagnetic coupling internal stress control module, 5-Material carrying module, 6-Material transfer robot, 7-Multi-field coupling processing cavity. Detailed Implementation

[0027] The technical solution of the present invention is further described below, but the scope of protection is not limited to what is described.

[0028] like Figure 1 As shown, the multi-field coupled stress control system of the present invention includes: Mechanical vibration internal stress control module 1 is used to apply mechanical vibration to the workpiece; Ultrasonic internal stress control module 2 is used to apply ultrasonic vibration or ultrasonic impact to the workpiece; The thermal stress control module 3 is used to adjust the workpiece temperature according to the set temperature curve. The electromagnetic coupling internal stress control module 4 is used to generate a controllable static magnetic field or dynamic magnetic field and / or electric field in the environment where the workpiece is located. Sensor array module, used to monitor the status of the workpiece and its environment in real time; The control module is electrically connected to the mechanical vibration internal stress control module 1, the ultrasonic internal stress control module 2, the thermal field internal stress control module 3, the electromagnetic coupling internal stress control module 4, and the sensor array module. It is used to coordinately control the output parameters and timing of the mechanical vibration internal stress control module 1, the ultrasonic internal stress control module 2, the thermal field internal stress control module 3, and the electromagnetic coupling internal stress control module 4 according to a preset multi-field coupling process model and in combination with the real-time state of the workpiece and its environment.

[0029] Specifically, the control module includes an industrial computer, PLC, data acquisition card, and drive and feedback circuits for mechanical vibration internal stress control module 1, ultrasonic internal stress control module 2, thermal field internal stress control module 3, and electromagnetic coupling internal stress control module 4. The sensor array module includes stress meters, temperature sensors, acoustic emission sensors, etc.

[0030] The mechanical vibration internal stress control module 1 has a vibration frequency of 5Hz~200Hz and an amplitude of 0.1mm~5mm. The ultrasonic internal stress regulation module 2 operates at a frequency of 15kHz to 60kHz and has an output power of 100W to 5kW.

[0031] Specifically, the mechanical vibration internal stress control module 1 typically consists of an eccentric motor or a hydraulic exciter, providing low-frequency, large-amplitude vibration for overall, macroscopic driving of dislocations and grain boundary sliding within the workpiece. The ultrasonic internal stress control module 2 consists of an ultrasonic generator and a transducer / amplifier, capable of contact impact or non-contact excitation, providing high-frequency, low-amplitude elastic waves for localized high-energy excitation, promoting the release of micro-stress concentration areas.

[0032] The thermal field internal stress control module 3 includes: Annealing heating unit 31, with a heating temperature range of room temperature to 800℃ and a temperature control accuracy of ±1℃, is used to heat the workpiece according to the set temperature rise curve; The cryogenic cooling unit 32 has a cooling temperature range of -190℃ to -50℃ and a controllable cooling rate, and is used to cool workpieces according to a set cooling curve.

[0033] Specifically, the annealing heating unit 31 is a resistance wire, infrared lamp, etc.; the cryogenic cooling unit 32 uses liquid nitrogen injection or compressor refrigeration to cool the workpiece, so that the internal stress control module 3 can achieve rapid and precise heating, heat preservation and cooling control in a wide temperature range of -190℃ to 800℃.

[0034] The cryogenic cooling unit 32 is connected to the multi-field coupling processing cavity 7 and is used to inject a low-temperature medium into the multi-field coupling processing cavity 7 or to cool the workpiece to a cryogenic temperature through contact cooling.

[0035] The electromagnetic coupling internal stress control module 4 can generate a static magnetic field with a strength of 0.1T~5T, an alternating magnetic field with a frequency of 10Hz~1000Hz, and / or a DC electric field or pulsed electric field with a field strength of 0~500V / cm.

[0036] Specifically, the electromagnetic coupling internal stress control module 4 consists of a water-cooled excitation coil (generating a magnetic field) and / or an insulating electrode plate (generating an electric field) placed around or parallel to the workpiece, which can generate static / alternating magnetic fields and / or electric fields separately or simultaneously.

[0037] The system also includes a sealable multi-field coupling processing cavity 7, in which the mechanical vibration internal stress control module 1, the ultrasonic internal stress control module 2, the thermal field internal stress control module 3, and the electromagnetic coupling internal stress control module 4 are all located.

[0038] The system also includes a material carrying module 5 and a material transfer robot 6 located in the multi-field coupling processing cavity 7. The mechanical vibration internal stress control module 1, the ultrasonic internal stress control module 2, the thermal field internal stress control module 3, and the electromagnetic coupling internal stress control module 4 are arranged around the material transfer robot 6. The material transfer robot 6 is used to realize the turnover of the workpiece between the mechanical vibration internal stress control module 1, the ultrasonic internal stress control module 2, the thermal field internal stress control module 3, and the electromagnetic coupling internal stress control module 4.

[0039] A control method for a multi-field coupled stress regulation system includes the following steps: Step 1: Place the workpiece to be processed on the material carrying module 5, and then install the sensor array module on the workpiece to be processed and inside the multi-field coupling processing cavity 7. Step 2: Input the basic information of the workpiece to be processed, the initial residual stress distribution characteristics, and the target performance requirements into the control module; Step 3: The control module generates and recommends a multi-field coupling processing timing based on its built-in algorithm; Step 4: The control module, based on the multi-field coupling process timing it generates and recommends, coordinates and controls the outputs of the mechanical vibration internal stress control module 1, ultrasonic internal stress control module 2, thermal field internal stress control module 3, and electromagnetic coupling internal stress control module 4 in real time, and performs closed-loop feedback adjustment based on the information collected by the sensor array module. Step 5: After completing the internal stress adjustment of the workpiece, the control module restores the multi-field coupling treatment cavity 7 and the workpiece to a safe temperature according to the set rate, removes all loads, and outputs an internal stress adjustment treatment report.

[0040] Specifically, the basic information of the workpiece to be processed in step two includes its shape, size, material, etc.

[0041] The multi-field coupling process sequence in step three includes multiple or all of the following stages: mechanical vibration-dominated stage, ultrasonic vibration or ultrasonic impact-dominated stage, annealing heating or annealing heat preservation stage, electromagnetic assisted vibration stage, cryogenic rapid cooling stage, cryogenic heat preservation and electromagnetic synergy stage, and low temperature recovery stage.

[0042] The multi-field coupling process sequence in step three includes a cryogenic-ultrasonic-electromagnetic synergistic processing process. After the workpiece reaches the cryogenic temperature, ultrasonic vibration and a strong pulsed electromagnetic field are applied simultaneously to promote the transformation of residual austenite and regulate micro-stress. The multi-field coupling process sequence in step three includes a vibration-annealing composite process, in which the workpiece is heated to 200℃~1200℃ and the temperature is kept below the recrystallization temperature of the workpiece. Then, mechanical vibration or ultrasonic vibration is applied to promote dislocation movement and stress homogenization.

[0043] Specifically, the workpiece is heated to 200℃~1200℃, ensuring that the temperature is below the recrystallization temperature of the workpiece. Then, mechanical or ultrasonic vibration is applied to reduce the yield strength of the material and facilitate dislocation movement induced by vibration.

[0044] In addition, the multi-field coupling process sequence also includes high-energy ultrasonic-electromagnetic synergistic processing: ultrasonic vibration and pulsed electromagnetic field are applied simultaneously in the heat preservation or cooling section, and the workpiece microstructure is homogenized by using magnetostriction and magneto-acoustic-elastic coupling effect.

[0045] Cryogenic-force-field composite treatment process: At a temperature near liquid nitrogen (-196℃), low-frequency mechanical vibration and pulsed magnetic field are applied while maintaining pressure. On the one hand, the deep cryogenic contraction is used to enhance the release of micro-stress, and on the other hand, the vibration and magnetic field are used to provide nucleation energy and driving force for the transformation of residual austenite to martensite, which greatly shortens the deep cryogenic treatment time.

[0046] Controlled low-temperature warming: After the internal stress of the workpiece is adjusted, the temperature is slowly increased in a controlled low-temperature or magnetic field environment to avoid thermal shock and secondary stress.

[0047] The control module incorporates either a fuzzy logic algorithm or a neural network algorithm. Based on real-time monitoring of the stress release rate and acoustic emission signal characteristics, the control module dynamically adjusts the vibration frequency, amplitude, and electromagnetic field parameters in subsequent stages.

Claims

1. A multi-field coupled stress control system, characterized in that: include: Mechanical vibration internal stress control module (1) is used to apply mechanical vibration to the workpiece; The ultrasonic internal stress control module (2) is used to apply ultrasonic vibration or ultrasonic impact to the workpiece. The thermal stress control module (3) is used to adjust the workpiece temperature according to the set temperature curve. The electromagnetic coupling internal stress control module (4) is used to generate a controllable static magnetic field or dynamic magnetic field and / or electric field in the environment where the workpiece is located. Sensor array module, used to monitor the status of the workpiece and its environment in real time; The control module is electrically connected to the mechanical vibration internal stress control module (1), the ultrasonic internal stress control module (2), the thermal field internal stress control module (3), the electromagnetic coupling internal stress control module (4), and the sensor array module. It is used to coordinately control the output parameters and timing of the mechanical vibration internal stress control module (1), the ultrasonic internal stress control module (2), the thermal field internal stress control module (3), and the electromagnetic coupling internal stress control module (4) according to the preset multi-field coupling process model and in combination with the real-time status of the workpiece and its environment.

2. The multi-field coupled stress control system as described in claim 1, characterized in that: The vibration frequency of the mechanical vibration internal stress control module (1) is 5Hz~200Hz, and the amplitude is 0.1mm~5mm. The ultrasonic internal stress control module (2) operates at a frequency of 15kHz to 60kHz and has an output power of 100W to 5kW.

3. The multi-field coupled stress control system as described in claim 1, characterized in that: The thermal stress control module (3) includes: Annealing heating unit (31) has a heating temperature range of room temperature to 800℃ and a temperature control accuracy of ±1℃. It is used to heat the workpiece according to the set temperature rise curve. The cryogenic cooling unit (32) has a cooling temperature range of -190℃ to -50℃ and a controllable cooling rate. It is used to cool workpieces according to a set cooling curve.

4. The multi-field coupled stress control system as described in claim 1, characterized in that: The electromagnetic coupling internal stress control module (4) can generate a static magnetic field with a strength of 0.1T~5T, an alternating magnetic field with a frequency of 10Hz~1000Hz, and / or a DC electric field or pulse electric field with a field strength of 0~500V / cm.

5. The multi-field coupled stress control system as described in claim 1, characterized in that: The system also includes a sealable multi-field coupling processing cavity (7), and the mechanical vibration internal stress control module (1), ultrasonic internal stress control module (2), thermal field internal stress control module (3) and electromagnetic coupling internal stress control module (4) are all located in the multi-field coupling processing cavity (7).

6. The multi-field coupled stress control system as described in claim 5, characterized in that: The system also includes a material carrying module (5) and a material transfer manipulator (6) located in the multi-field coupling processing cavity (7). The mechanical vibration internal stress control module (1), the ultrasonic internal stress control module (2), the thermal field internal stress control module (3) and the electromagnetic coupling internal stress control module (4) are arranged around the material transfer manipulator (6). The material transfer manipulator (6) is used to realize the turnover of the workpiece between the mechanical vibration internal stress control module (1), the ultrasonic internal stress control module (2), the thermal field internal stress control module (3) and the electromagnetic coupling internal stress control module (4).

7. A control method for a multi-field coupled stress regulation system as described in claim 6, characterized in that: Includes the following steps: Step 1: Place the workpiece to be processed on the material carrying module (5), and then install the sensor array module on the workpiece to be processed and inside the multi-field coupling processing cavity (7); Step 2: Input the basic information of the workpiece to be processed, the initial residual stress distribution characteristics, and the target performance requirements into the control module; Step 3: The control module generates and recommends a multi-field coupling processing timing based on its built-in algorithm; Step 4: The control module, based on the multi-field coupling process timing it generates and recommends, coordinates and controls the outputs of the mechanical vibration internal stress control module (1), ultrasonic internal stress control module (2), thermal field internal stress control module (3) and electromagnetic coupling internal stress control module (4) in real time, and performs closed-loop feedback adjustment based on the information collected by the sensor array module. Step 5: After completing the internal stress adjustment of the workpiece, the control module restores the multi-field coupling treatment cavity (7) and the workpiece to a safe temperature according to the set rate, removes all loads, and outputs an internal stress adjustment treatment report.

8. The control method for the multi-field coupled stress regulation system as described in claim 7, characterized in that: The multi-field coupling process sequence in step three includes multiple or all of the following stages: mechanical vibration-dominated stage, ultrasonic vibration or ultrasonic impact-dominated stage, annealing heating or annealing heat preservation stage, electromagnetic assisted vibration stage, cryogenic rapid cooling stage, cryogenic heat preservation and electromagnetic synergy stage, and low temperature recovery stage.

9. The control method for the multi-field coupled stress regulation system as described in claim 7, characterized in that: The multi-field coupling process sequence in step three includes a cryogenic-ultrasonic-electromagnetic synergistic processing process. After the workpiece reaches the cryogenic temperature, ultrasonic vibration and a strong pulsed electromagnetic field are applied simultaneously to promote the transformation of residual austenite and regulate micro-stress. The multi-field coupling process sequence in step three includes a vibration-annealing composite process, in which the workpiece is heated to 200℃~1200℃ and the temperature is kept below the recrystallization temperature of the workpiece. Then, mechanical vibration or ultrasonic vibration is applied to promote dislocation movement and stress homogenization.

10. The control method for the multi-field coupled stress regulation system as described in claim 7, characterized in that: The algorithm built into the control module is either a fuzzy logic algorithm or a neural network algorithm.

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