Torsion Beam Pulling Process Residual Stress Reduction
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Solution Overview
Problem
Existing methods for manufacturing torsion beams struggle to efficiently improve fatigue properties while increasing initial and manufacturing costs, such as through quenching, tempering, and shot-peening, which are not always effective and costly.
Innovation Solution
A torsion beam manufacturing method involving a pulling process that applies a tensile force to the connection region of the torsion beam material, reducing residual stress without the need for post-treatments like heat treatment, using a manufacturing apparatus with holding mechanisms and driving mechanisms to apply the tensile force along the longitudinal direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If quenching, tempering, and shot-peening are applied to improve fatigue properties, then fatigue properties are improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The invention extracts and eliminates the need for complex post-manufacturing treatments (quenching, tempering, shot-peening) by integrating the stress relief function directly into the forming process itself. The hydro-forming process is modified to include internal pressure application during forming, which simultaneously creates the desired shape and reduces residual stress, thereby removing the need for separate treatment steps.
Solution Approach 2:
The invention merges the forming process and stress relief treatment into a single integrated hydro-forming operation. By applying internal pressure during the forming process, the treatment that would traditionally require separate quenching, tempering, and shot-peening steps is combined with the shaping operation, reducing process complexity while maintaining fatigue property improvements.
2Reliability
If quenching, tempering, and shot-peening are applied to improve fatigue properties, then fatigue properties are improved, but manufacturing cost increases
Solution Approach 1:
The invention extracts and eliminates the need for costly post-manufacturing treatments (quenching, tempering, shot-peening) by integrating the stress relief function directly into the forming process itself. The hydro-forming process is modified to include internal pressure application during forming, which simultaneously creates the desired shape and reduces residual stress, thereby removing the need for separate treatment steps.
Solution Approach 2:
The invention merges the forming process and stress relief treatment into a single integrated hydro-forming operation. By applying internal pressure during the forming process, the treatment that would traditionally require separate quenching, tempering, and shot-peening steps is combined with the shaping operation, reducing process complexity while maintaining fatigue property improvements.
3Productivity
If press forming or hydro-form forming is used to manufacture torsion beam, then manufacturing efficiency is improved, but residual stress remains high causing metal fatigue
Solution Approach 1:
The invention applies preliminary action by incorporating stress relief measures during the forming process itself rather than as a subsequent step. Internal pressure is applied during hydro-forming to prevent residual stress formation in the first place, particularly in the connection portions between shape-changing regions and uniform sections, thereby maintaining manufacturing efficiency while improving fatigue resistance.
Solution Approach 2:
The invention changes the parameters of the hydro-forming process by applying internal pressure during forming. This parameter modification allows the forming process to simultaneously achieve the desired shape and reduce residual stress, particularly in connection portions, thereby improving fatigue resistance without sacrificing manufacturing efficiency.
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 efficiently manufactures torsion beams with enhanced fatigue properties by reducing residual stress, eliminating the need for costly post-treatments and improving manufacturing efficiency.
Implementation Method 1
pulling process of applying a tensile force in the longitudinal direction to at least the connection region
Implementation Method 2
reducing residual stress without the need for post-treatments like heat treatment
Data Source
AI summary
This torsion beam manufacturing method is a method of manufacturing a torsion beam that includes a uniformly shaped closed cross-sectional portion of which a cross section orthogonal to a longitudinal direction is a closed cross section having a substantial V-shape or a substantial U-shape at any position in the longitudinal direction, and a shape changing portion which has a connection region leading to the uniformly shaped closed cross-sectional portion and including a closed cross section having a shape different from the shape of the closed cross section of the uniformly shaped closed cross-sectional portion. The torsion beam manufacturing method includes pulling process of applying a tensile force in the longitudinal direction to at least the connection region of a torsion beam material including the uniformly shaped closed cross-sectional portion and the shape changing portion, to obtain the torsion beam.