Ultrasonic Roller Burnishing With Feedback Residual Stress Control
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Solution Overview
Problem
Conventional ultrasonic roller burnishing methods cannot control the value of induced residual compressive stress, making it difficult to meet performance requirements for components that need different stress values in various areas.
Innovation Solution
An ultrasonic roller burnishing system and method that adjusts the pressing depth, back pressure, input current, and feed rate based on expected residual compressive stress and real-time output power to generate a controlled range of residual compressive stress in workpieces, using a controller to optimize the machining process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional ultrasonic roller burnishing method is used, then residual compressive stress can be induced into the component, but the value of the induced residual compressive stress cannot be controlled
Solution Approach 1:
The system employs a closed-loop feedback control mechanism where the controller continuously monitors the actual residual compressive stress values induced in the component and compares them against the preset target values. Based on this feedback, the controller automatically adjusts process parameters (such as roller pressing force, ultrasonic power, and feed rate) to ensure the induced stress falls within the desired range, thereby achieving precise control that was impossible with conventional open-loop methods
Solution Approach 2:
The invention achieves control over residual compressive stress by dynamically adjusting multiple process parameters including the pressing depth of the roller, the back pressure applied during burnishing, the input current to the ultrasonic vibration unit, and the feed rate. By changing these parameters in combination, the system can precisely control the magnitude and distribution of induced residual compressive stress to meet different performance requirements
2Adaptability or versatility
If different residual compressive stress values are required for different areas of the component, then performance requirements can be met, but conventional ultrasonic roller burnishing method cannot provide area-specific stress control
Solution Approach 1:
The system implements local quality control by allowing different segments or zones of the component surface to receive customized burnishing parameters. The controller can preset different target residual compressive stress values for different areas, and the ultrasonic roller can apply area-specific pressing forces and feed rates, thereby inducing appropriate stress levels in each zone according to its specific performance requirements
3Reliability
If precise control of residual compressive stress is implemented, then fatigue life and corrosion resistance are enhanced, but system complexity increases
Solution Approach 1:
The controller serves multiple functions within a single integrated unit: it presets target residual compressive stress values, monitors actual stress induction in real-time, compares measured values against targets, and adjusts process parameters accordingly. This multi-functionality achieves precise stress control and enhanced component reliability without requiring multiple separate control devices, thereby limiting the increase in overall system complexity
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 precise control of residual compressive stress distribution in components, enhancing their fatigue life, corrosion resistance, and stress corrosion cracking resistance by accurately inducing desired stress levels in specific areas.
Implementation Method 1
vibrating the roller at an ultrasonic frequency under a back pressure, wherein the vibrating of the roller is driven by an ultrasonic vibration unit
Data Source
AI summary
An ultrasonic roller burnishing system comprises a roller and a controller. The roller is configured to be pressed against a surface of a workpiece to a pressing depth, roll on the surface at a feed rate, and vibrate at an ultrasonic frequency under a back pressure. The roller is pressed and rolled by a motion unit which is driven by a drive motor. The vibrating of the roller is driven by an ultrasonic vibration unit with an input current inputted thereinto. The controller is configured to adjust at least one of the pressing depth, the back pressure, the input current and the feed rate based on an expected residual compressive stress and a real time output power of the drive motor, to generate a residual compressive stress in the workpiece which is in an expected range predetermined based on the expected residual compressive stress.