Rotational Stress Relief Control for Repeatable Residual Enlargement
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Solution Overview
Problem
The existing methods for relieving residual stresses in forged parts, particularly in turbomachine components, face challenges in achieving repeatability due to variations in part geometry, composition, and material properties, leading to inconsistent deformation during machining and increased manufacturing times and costs.
Innovation Solution
A method that automatically adjusts the rotation speed of forged parts to achieve a targeted residual enlargement by measuring and analyzing the radial enlargement and rotation speed data to determine a specific affine function, allowing for real-time adaptation without operator intervention, using contactless sensors and a computer system to control the deformation phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single target rotation speed is used as the stoppage parameter for the acceleration phase, then the control of the stress relief operation is simplified, but the residual enlargements obtained vary significantly between different parts due to variations in weight, composition, and geometry
Solution Approach 1:
The patent applies dynamics by making the target rotation speed adaptive rather than fixed. The system dynamically adjusts the target speed based on real-time measurements of actual rotation speed and radial enlargement, allowing the control parameter to evolve during the operation according to the specific part's characteristics, thereby resolving the contradiction between simplified control and consistent results
Solution Approach 2:
The patent implements feedback control by continuously measuring the actual rotation speed and radial enlargement during the acceleration phase, then using these measurements to recalculate and update the target rotation speed. This closed-loop feedback mechanism ensures that each part receives customized control parameters based on its actual behavior, achieving both ease of operation through automated control and manufacturing precision through adaptive adjustment
2Manufacturing precision
If the method is adapted part by part to achieve consistent results, then the manufacturing precision is improved, but the manufacturing time and production costs increase
Solution Approach 1:
The patent applies self-service by enabling the system to automatically determine optimal control parameters for each part without requiring operator intervention or pre-programmed part-specific data. The system measures the part's actual characteristics during operation and autonomously adjusts the target rotation speed, achieving high manufacturing precision while maintaining fast production cycles through automated self-adaptation
Solution Approach 2:
The patent implements parameter changes by dynamically modifying the target rotation speed parameter based on real-time measurements of actual speed and radial enlargement. This allows the system to adapt to each part's unique characteristics (weight, composition, geometry) by changing the control parameter on-the-fly, achieving consistent stress relief results without requiring time-consuming manual setup or part-by-part calibration
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
This method ensures consistent and repeatable stress relief, adapting to the unique characteristics of each part, reducing manufacturing time and costs by achieving the desired final residual enlargement with high precision and repeatability.
Implementation Method 1
rotating at high speed a part, ideally a revolving part, in order to deform it plastically and thus redistribute and relieve the internal stresses induced during upstream elaboration and transformation operations
Implementation Method 2
deform it plastically and thus redistribute and relieve the internal stresses
Data Source
AI summary
A method for relieving residual stresses in a part includes increasing the rotation speed, which includes measuring, at a first given instant, values representative of the rotation speed and the radial enlargement; measuring, at a second given instant after the first instant, values representative of the rotation speed and the radial enlargement; determining a leading coefficient of a first affine function from the preceding values; determining a target radial enlargement value as a function of a value representative of the rotation speed, in the form of a second affine function, the origin of which is the value of a desired final residual enlargement and the leading coefficient of which is the leading coefficient of the first affine function; stopping the increase in rotation speed of the part from the moment that the actual enlargement of the rotating part corresponds to the target relative radial enlargement value that has been determined.