Loaded Spring Stress Screening With Cos α X-Ray Diffraction
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Solution Overview
Problem
Current methods fail to accurately inspect stress distribution in springs under load, which is crucial for weight reduction in automotive parts, as they rely on destructive testing for residual stress and simulation for shape-induced stress, lacking a non-destructive evaluation method for actual products under load.
Innovation Solution
A method involving applying a load to a spring using a jig, measuring stress with X-ray diffraction, and determining if the measured stress meets criteria, allowing for the identification and elimination of defective products, thereby ensuring accurate stress distribution evaluation under load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If destructive inspection is used to measure residual stress after shot peening, then measurement precision is improved, but productivity is worsened due to loss of inspected products
Solution Approach 1:
The patent replaces destructive mechanical testing with non-destructive X-ray diffraction technology to measure residual stress. This substitution allows stress measurement without destroying the spring structure, enabling both high measurement precision and maintained productivity through non-contact, non-invasive inspection methodology.
Solution Approach 2:
The patent introduces X-ray diffraction as an intermediary measurement method that indirectly measures residual stress without direct contact or destruction of the spring. This intermediary approach bridges the gap between needing accurate stress data and maintaining product integrity for continued use.
2Measurement precision
If finite element method simulation is used to inspect stress distribution, then measurement precision is improved for shape-induced stress, but reliability is worsened because it cannot account for actual residual stress from shot peening
Solution Approach 1:
The patent merges simulation-based stress analysis with experimental X-ray diffraction measurement results. By combining the shape-induced stress calculation from finite element analysis with the actual residual stress measurement from X-ray diffraction, the method achieves comprehensive and reliable total stress evaluation that accounts for both theoretical and actual stress components.
Solution Approach 2:
The patent uses X-ray diffraction measurement results as feedback to validate and refine the finite element simulation model. The measured residual stress data provides real-world verification that improves the accuracy of subsequent simulations, creating a closed-loop system that continuously enhances stress prediction reliability.
3Productivity
If spring weight is reduced for automotive part optimization, then productivity is improved through material efficiency, but reliability is worsened due to increased stress concentration risks
Solution Approach 1:
The patent applies local quality optimization by using X-ray diffraction to measure and verify stress distribution at specific critical locations on the spring. This localized measurement approach enables targeted validation of stress concentrations in weight-reduced spring designs, ensuring that material efficiency gains do not compromise structural reliability at critical points.
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
Enables the manufacturing of springs with inspected stress distribution under load, facilitating stable weight reduction and improved quality control by directly measuring stress using X-ray diffraction, ensuring compliance with design criteria.
Implementation Method 1
measuring the stress on a surface of an active part of the spring using X-ray diffraction with cos a method
Implementation Method 2
measuring the stress on a surface of an active part of the spring using X-ray diffraction with cos a method
Data Source
AI summary
Provided is a method of manufacturing a spring for inspecting the stress distribution of the spring under load. The method for manufacturing a spring (1) includes the steps of applying a load to the spring (1), measuring the stress of the spring (1) under the load, and releasing the load applied to the spring (1), the measuring the stress of the spring (1) being made by measuring the stress on the surface of the active part of the spring (1) using X-ray diffraction with the cos α method, and the method further including the step of determining whether the magnitude of the stress of the spring (1) meets a criterion.