Fixed Value Residual Stress Test Block Manufacturing
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Solution Overview
Problem
Current methods for creating a standard test block for absolute residual stress measurement are complex and lack a simple, accurate, and reliable way to produce a fixed value residual stress test block for ultrasonic non-destructive testing systems.
Innovation Solution
A fixed value residual stress test block is manufactured by welding two rectangular metal blocks to a main body, which is deformed under pressure to generate residual stress, allowing for controlled stress values through precise deformation and welding techniques, and stored in a controlled environment to maintain stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods (x-ray diffraction with cast blocks or bending steel) are used to create residual stress test blocks, then fixed residual stress values can be achieved, but the manufacturing process becomes overly complex and difficult to implement
Solution Approach 1:
The test block is divided into a main body and separate welded blocks that are attached to opposite sides. This segmentation allows the main body to be simply deformed and welded, creating residual stress without requiring complex casting or bending processes. The welded blocks serve as reference regions that maintain dimensional stability while the main body generates the required residual stress through deformation and welding.
Solution Approach 2:
The invention changes the physical state and stress parameters of the main body through controlled deformation and welding processes. By applying deformation (changing shape parameters) and then welding the welded blocks to the deformed main body, fixed residual stress values are generated. This approach transforms a complex manufacturing problem into a controlled parameter change process that is simpler and more reliable.
2Ease of manufacture
If simple casting methods are used to create test blocks, then manufacturing is easier, but the residual stress values cannot be precisely controlled or standardized
Solution Approach 1:
The main body is deformed before the welded blocks are attached. This preliminary deformation action creates the stress state needed, and then the welded blocks are fixed to lock in the residual stress. By performing the deformation action in advance and then securing the structure through welding, the method achieves both manufacturing simplicity and precise stress control.
Solution Approach 2:
The welded blocks act as intermediary elements that transfer and stabilize the stress state. When the main body is deformed and then welded to these blocks, the welding process serves as an intermediary mechanism that locks in the residual stress. This intermediary approach allows simple deformation to result in precisely controlled fixed stress values.
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
The solution provides a simple, accurate, and reliable method for producing a fixed value residual stress test block that maintains stable residual stress, enabling precise correction of ultrasonic non-destructive testing results.
Implementation Method 1
The main body deforms due to bearing a pressure in up and down direction, and generates residual stress
Implementation Method 2
The welded blocks are welded to two opposite sides of the main body
Data Source
AI summary
A fixed value residual stress test block, comprising a main body (1) and two welded blocks (2); the main body (1) and the welded blocks (2) are all rectangular metal blocks; the welded blocks (2) are welded onto the two opposite side surfaces of the main body (1); the main body (1) is deformed under the upper and lower pressures and generates residual stress. The fixed value residual stress test block has a simple structure.