Refinement Layer Stress Relief for Durable Workpiece Surfaces
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Solution Overview
Problem
Existing manufacturing methods for workpieces with refinement layers, such as brake discs, often result in localized stresses and deformations due to thermal input, leading to premature detachment of the refinement layer and the need for post-machining to compensate for shielding issues.
Innovation Solution
A manufacturing method that involves applying a refinement layer to a workpiece and then reducing stresses in the refinement layer and treatment surface using methods like stress-relief annealing, roller-burnishing, hammering, or pressing, thereby improving the bond strength and eliminating the need for post-machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a refinement layer is applied using high-speed flame spraying or diffusion method, then the workpiece gains protective or functional properties, but localized stresses and partial deformation occur
Solution Approach 1:
The patent applies stress-relief annealing as a preliminary treatment step after refinement layer application but before final machining or operation. This preliminary action reduces localized stresses while the refinement layer is still present, preventing premature detachment and reducing the need for excessive material allowances.
Solution Approach 2:
The patent changes the thermal parameters by applying controlled heat treatment (stress-relief annealing) to modify the stress state in the refinement layer. By adjusting temperature and holding time parameters, the internal stresses are reduced without compromising the bond strength or functional properties of the refinement layer.
2Manufacturing precision
If post-machining is performed to compensate for shielding, then the workpiece achieves required dimensional accuracy, but material amount, mass and production time increase
Solution Approach 1:
The patent performs stress-relief annealing as a preliminary action before final machining operations. This preliminary stress reduction prevents additional deformation during subsequent machining, allowing for more efficient machining with less material removal and reduced production time.
Solution Approach 2:
The patent converts the harmful effect of thermal deformation into a beneficial process by intentionally applying controlled heat treatment that creates compressive stresses. These compressive stresses counteract the shielding effect and prevent future deformation, turning a potential problem into a solution that reduces machining requirements.
3Manufacturing precision
If material allowance is made for shielding compensation, then the workpiece can be machined to required precision, but the amount of material, mass increases
Solution Approach 1:
The patent changes the stress state parameters through stress-relief annealing, transforming tensile stresses into compressive stresses. This parameter change allows the workpiece to maintain required surface flatness with minimal material allowance, thereby reducing the overall mass of the workpiece.
4Reliability
If stresses are reduced in the refinement layer, then the fatigue strength of the bond is improved, but additional processing steps are required
Solution Approach 1:
The patent combines the stress-relief annealing step with the existing refinement layer application process. By integrating these steps, the patent reduces the number of separate processing operations while achieving both the protective coating application and stress reduction in a coordinated manner.
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 method effectively reduces stresses in the refinement layer, enhancing the fatigue strength of the bond between the refinement layer and the treatment surface, and reducing the roughness and increasing the surface density of the refinement layer, which leads to improved long-term strength and reduced material usage.
Implementation Method 1
stress-relief annealing
Implementation Method 2
thermal input during the application of the refinement layer
Implementation Method 3
roller-burnishing
Implementation Method 4
hammering
Data Source
AI summary
The invention relates to a finishing method for a workpiece with a finishing layer, having the following steps: a. providing a workpiece with a treatment surface; and b. providing the treatment surface with a finishing layer. The finishing method is primarily characterized in that the method has at least the following step: c. reducing stresses in the finishing layer. The invention additionally relates to a workpiece with a finishing layer, wherein the finishing layer is re-compressed and/or the stress in the finishing layer is neutral or a compressive stress. By virtue of the aforementioned finishing method and the workpiece, a high quality and a long service life of the finishing layer can be achieved using inexpensive means.