Thermal Shrinkage Prediction Using Multi-Zone Strain Modeling
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Solution Overview
Problem
Conventional thermal shrinkage methods for predicting transverse shrinkage and residual stress distribution in large or complex structures have significant deviations compared to thermal elastic-plastic analysis, leading to inaccurate and time-consuming predictions.
Innovation Solution
A modified thermal shrinkage method involving multiple shrinkage zones with distinct temperature changes and corresponding strain applications in an elastic or elastic-plastic analysis, allowing for precise prediction of deformations and residual stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If thermal elastic-plastic analysis is used to predict deformation and residual stress, then prediction accuracy is improved, but calculation time increases significantly and analysis becomes extremely difficult for large or complex structures
Solution Approach 1:
The patent segments the heat-affected zone into multiple shrinkage zones based on different temperature ranges (e.g., Ac3 transformation point, Ac1 transformation point, 500℃, 300℃). Each zone is assigned specific shrinkage strain characteristics, allowing the complex thermal elastic-plastic analysis to be simplified into manageable segments that can be processed more efficiently while maintaining prediction accuracy.
Solution Approach 2:
The patent applies different shrinkage strain values and temperature change parameters to different local regions (shrinkage zones) within the heat-affected area. By assigning location-specific thermal and mechanical properties to each zone, the method captures local variations in deformation behavior without requiring full thermal elastic-plastic analysis of the entire structure.
2Loss of time
If conventional thermal shrinkage method is used for quick analysis, then calculation time is reduced, but prediction accuracy of transverse shrinkage and residual stress distribution deteriorates with large deviation from thermal elastic-plastic analysis
Solution Approach 1:
The patent introduces specific parameter changes by defining multiple shrinkage zones with distinct temperature thresholds (Ac3, Ac1, 500℃, 300℃) and assigning different shrinkage strain values to each zone. This parameter differentiation allows the simplified thermal shrinkage method to capture the nuanced deformation behavior that conventional methods miss, thereby improving prediction accuracy while maintaining computational efficiency.
Solution Approach 2:
By segmenting the heat-affected zone into multiple temperature-based shrinkage zones, the patent enables the simplified method to account for different deformation mechanisms occurring at different temperature ranges, thus improving accuracy without requiring the computational resources of full thermal elastic-plastic analysis.
3Device complexity
If single shrinkage zone with uniform temperature change is assumed, then analysis complexity is reduced, but manufacturing precision of deformation prediction deteriorates
Solution Approach 1:
The patent divides the heat-affected zone into multiple shrinkage zones based on temperature thresholds, with each zone having its own shrinkage strain characteristics. This segmentation increases prediction accuracy by capturing spatial variations in deformation behavior while keeping the analysis approach relatively simple and systematic.
Solution Approach 2:
The patent assigns different thermal and mechanical parameters to different local regions (shrinkage zones) within the heat-affected area. By making the analysis locally adaptive rather than uniformly simplified, the method achieves better deformation prediction accuracy without proportionally increasing overall analysis 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
Accurately predicts deformations and residual stresses in a shorter time frame, aligning with thermal elastic-plastic analysis results, while reducing computational burden.
Implementation Method 1
a transverse shrinkage and a residual stress distribution calculated by analysis using the conventional thermal shrinkage method have a large deviation from a transverse shrinkage and a residual stress distribution calculated using thermal elastic-plastic analysis
Implementation Method 2
performing an elastic analysis or an elastic-plastic analysis by giving a first shrinkage strain calculated from the first change in temperature to the first shrinkage zone
Implementation Method 3
performing an elastic analysis or an elastic-plastic analysis by giving a second shrinkage strain calculated from the second change in temperature to the second shrinkage zone
Data Source
AI summary
The present invention provides a prediction method (modified thermal shrinkage method) that can quickly and accurately predict a deformation or a residual stress caused by returning temperature of an object subjected to heating to room temperature. The prediction method of the present invention is a method for predicting a deformation or a residual stress caused by returning temperature of an object subjected to heating to room temperature, including: a condition setting step of setting a first shrinkage zone and a second shrinkage zone in an analytical model of the object, and setting a first change in temperature of the first shrinkage zone and a second change in temperature of the second shrinkage zone; and an analysis step of performing an elastic analysis or an elastic-plastic analysis by giving a first shrinkage strain calculated from the first change in temperature to the first shrinkage zone and by giving a second shrinkage strain calculated from the second change in temperature to the second shrinkage zone.