Parameter Inversion for Residual Stress Control
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Solution Overview
Problem
Current methods for controlling residual stress in processed workpieces are qualitative and resource-intensive, relying on trial and error with significant human, material, and financial costs, and are not adaptable to changes in workpiece materials.
Innovation Solution
A method for calculating processing parameters using parameter inversion equations to achieve a preset residual stress distribution, involving data acquisition, fitting signal-variable curves, and linear inversion equations to determine optimal processing parameters for machine tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If trial and error method is used to control residual stress, then residual stress distribution can be obtained, but human, material and financial resources are consumed significantly
Solution Approach 1:
The patent inverts the traditional trial-and-error approach by establishing an inverse mapping from desired residual stress distribution to processing parameters. Instead of testing multiple parameter combinations to find the desired stress state, the system calculates the required parameters directly from the target stress distribution using inverse algorithms, thereby eliminating resource-consuming iterative testing.
Solution Approach 2:
The patent replaces the mechanical trial-and-error process with a computational system that uses mathematical models and inverse algorithms to directly determine processing parameters. This substitution of computational methods for physical experimentation significantly reduces the consumption of human, material, and financial resources while maintaining manufacturing precision.
2Manufacturing precision
If trial and error method is used to control residual stress, then residual stress distribution can be obtained, but the cycle repeats until required residual stress distribution is obtained
Solution Approach 1:
The patent inverts the traditional trial-and-error approach by establishing an inverse mapping from desired residual stress distribution to processing parameters. Instead of testing multiple parameter combinations to find the desired stress state, the system calculates the required parameters directly from the target stress distribution using inverse algorithms, thereby eliminating time-consuming iterative testing.
Solution Approach 2:
The patent performs preliminary calculation of the optimal processing parameters before actual processing begins. By using inverse algorithms to determine the required parameters in advance based on the desired residual stress distribution, the system eliminates the need for repeated trial processing cycles, significantly reducing the overall processing time.
3Adaptability or versatility
If test method is used to find suitable processing parameters, then residual stress control can be achieved, but when workpiece material changes, the test method needs to be used again
Solution Approach 1:
The patent creates a universal computational system that can handle different workpiece materials through a standardized inverse algorithm framework. The system incorporates material properties as input parameters to the mathematical model, allowing it to adapt to different materials without requiring complete retesting. This universal approach maintains material adaptability while avoiding repeated resource consumption.
Solution Approach 2:
The patent enables adaptation to different materials by changing the input parameters (material properties) in the mathematical model rather than changing the fundamental calculation methodology. When workpiece material changes, only the material-specific parameters need to be updated in the model, while the inverse algorithm framework remains the same, thereby maintaining versatility without repeating the entire testing process.
4Strength
If qualitative control methods such as shot peening and heat treatment are used, then residual compressive stress can be increased, but quantitative control of residual stress is not achieved
Solution Approach 1:
The patent replaces qualitative control methods with a computational system that uses mathematical models and inverse algorithms to directly calculate the processing parameters needed to achieve a specific target residual stress value. This substitution enables precise quantitative control by computing the exact parameters required, rather than relying on qualitative adjustments through trial and error or experience-based methods.
Solution Approach 2:
The patent implements a feedback mechanism where the desired residual stress distribution serves as the target input to the inverse algorithm. The system continuously refines the calculation of processing parameters based on the difference between the current and target stress states, enabling precise quantitative control. This feedback approach allows the system to achieve the exact required residual stress level rather than relying on qualitative adjustments.
Data Source
AI summary
The present invention belongs to the field of processing residual stress, and discloses a method for calculating processing parameters for residual stress control by parameter inversion. This method comprises: (a) extracting a characteristic index reflecting the residual stress distribution characteristic from a residual stress distribution curve; (b) respectively presetting initial values of processing parameters for residual stress control, calculating an initial value of the characteristic index, and drawing curves of the characteristic index over the respective processing parameters to obtain respective fitted curves; (c) respectively establishing a relation formula between respective characteristic index increment of the processing parameters and the fitting curve; and (d) assigning the values and performing inversion calculation to obtain the required processing parameters. The present invention is simple in operation, reduces the number of tests, lowers the production cost, improves the processing residual stress distribution of the workpiece and improves the anti-fatigue life of the components.