Elastic Wave Array Treatment for Residual Stress Homogenization
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Solution Overview
Problem
Existing methods are inadequate for reducing and homogenizing residual stress in complex, intricately structured aluminum alloy components, particularly those with uneven stress distributions caused by welding and milling processes, as they either require excessive time or are unsuitable for components with precise external dimensions or intricate structures.
Innovation Solution
A device and method utilizing an array of high-energy elastic waves, where a tubular body with embedded exciting wedges and exciters emits waves perpendicularly to the component, controlled by a multi-channel signal amplifier and excitation control module, to reduce and homogenize residual stress, while a clamping device ensures uniform pressure and deformation control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If natural aging method is used to reduce residual stress, then residual stress is reduced, but processing time becomes excessively long (months or years)
Solution Approach 1:
The patent applies high-energy elastic wave vibration through exciters mounted on the component surface. The vibration parameters (frequency, amplitude, duration) are specifically controlled to induce stress relaxation and homogenization in the component, achieving residual stress reduction in hours rather than months or years required by natural aging
Solution Approach 2:
The patent changes the physical state and parameters of the component by applying controlled mechanical vibration with specific frequency ranges (typically 20-200 Hz) and amplitudes. This parameter change accelerates the stress relaxation process that would otherwise occur naturally over extended periods, dramatically reducing processing time while maintaining effectiveness
2Strength
If vibration impaction method is used, then residual stress is reduced in plate and disk components, but it performs poorly on components with intricate structures such as tanks and shafts
Solution Approach 1:
The patent segments the vibration treatment into multiple localized zones by placing multiple exciters at different positions on the component surface. Each exciter treats a specific region, allowing the system to handle complex geometries and intricate structures that cannot be treated uniformly. The treatment can be applied selectively to different areas with different stress states
Solution Approach 2:
The patent creates a universal treatment system that can handle various component types (plates, disks, tanks, shafts, and other intricate structures) through the same basic mechanism of high-energy elastic wave vibration. The system is adaptable to different geometries by adjusting exciter positions, orientations, and operating parameters, making it universally applicable across diverse component types
3Strength
If annealing or tempering is used to reduce residual stress, then residual stress is reduced, but processing time requires at least three to five days and requires strict fire control operation
Solution Approach 1:
The patent replaces the thermal field (heat treatment) with a mechanical field (vibration treatment). Instead of using annealing or tempering which require prolonged heating and cooling cycles (3-5 days), the system uses high-energy elastic wave vibration to directly induce stress relaxation through mechanical energy input, achieving the same stress reduction effect in hours without thermal processing
Solution Approach 2:
The patent changes the physical state and parameters of the component by applying controlled mechanical vibration with specific frequency ranges (typically 20-200 Hz) and amplitudes. This parameter change accelerates the stress relaxation process that would otherwise occur naturally over extended periods, dramatically reducing processing time while maintaining effectiveness
4Strength
If cold pressing is used to reduce residual stress in forgings, then residual stress is reduced by stretching, but it is not suitable for welded components or components with precise external dimension requirements
Solution Approach 1:
The patent applies local quality treatment by positioning exciters at specific locations on the component surface where residual stress needs to be reduced. The vibration treatment can be concentrated on welded areas, heat-affected zones, or any specific region with high residual stress, while leaving other areas unaffected. This localized approach preserves external dimensions and surface quality in precision areas
Solution Approach 2:
The patent changes the physical state and parameters of the component by applying controlled mechanical vibration with specific frequency ranges (typically 20-200 Hz) and amplitudes. This parameter change accelerates the stress relaxation process that would otherwise occur naturally over extended periods, dramatically reducing processing time while maintaining effectiveness
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively reduces and homogenizes residual stress in components with complex structures and stress distributions, providing remarkable deformation control, especially for aluminum alloy components, by optimizing energy impact and frequency settings based on pre-detection data.
Implementation Method 1
a device and a method for reducing and homogenizing residual stress by array of high-energy elastic waves
Data Source
AI summary
A device and method for reducing and homogenizing residual stress of a component by an array of high-energy elastic waves. The device includes a tubular body consisting of at least two elements, multiple first through holes and a clamping device provided on an outer side of the tubular body. Exciters are connected with exciting wedges so that an end face of each of the exciting wedges is closely coupled to a surface of the component. A connection portion is coupled to an emitting end of each of the exciters, where the axis of the emitting end coincides with a normal line at a pressed surface of the component A multi-channel signal amplifier is electrically connected to each of the exciters and a multi-channel excitation control module is electrically connected to the multi-channel signal amplifier.