Vibration-Assisted Rolling for Thin-Walled Surface Treatment
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Solution Overview
Problem
Existing surface treatment methods for thin-walled aerospace components fail to effectively impart compressive stresses without deforming the geometry, necessitating high static pressure loads that can distort the components.
Innovation Solution
A method and system involving a roller that applies a static pressure load while concurrently transmitting vibrations into the material, reducing the need for excessive static pressure by combining rolling and vibration operations to impart compressive stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high static pressure loads are applied to impart compressive stresses in thin-walled components, then damage tolerance and fatigue life are improved, but component geometry is deformed
Solution Approach 1:
The patent applies ultrasonic vibrations through the roller during the rolling operation. The vibration frequency (20 kHz or higher) and amplitude are controlled to enhance the imparting of compressive stresses while reducing the static pressure load required, thereby preventing geometry deformation in thin-walled components
Solution Approach 2:
The patent changes the physical parameters of the treatment process by introducing vibration frequency and amplitude as additional controllable parameters. The controller adjusts vibration frequency (20 kHz or higher) and amplitude based on wall thickness and applied pressure, optimizing the balance between imparting compressive stresses and preventing geometry deformation
2Stress or pressure
If high static pressure loads are used to treat thin-walled components, then compressive stresses are effectively imparted, but the component undergoes unwanted deformation
Solution Approach 1:
Ultrasonic vibrations are transmitted through the roller into the component material during rolling. This vibration assistance enhances stress imparting efficiency, allowing effective compressive stress treatment at reduced static pressure loads that prevent geometry deformation in thin-walled components
Solution Approach 2:
The system dynamically adjusts vibration frequency and amplitude during the rolling operation based on real-time conditions. The controller modifies these parameters according to wall thickness and applied pressure, enabling adaptive optimization of stress imparting while preventing deformation
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 approach enhances damage tolerance and fatigue life of thin-walled components by up to ten times, maintaining component geometry without deformation.
Implementation Method 1
transmitting vibrations into the material of the component through the roller
Implementation Method 2
The vibrations may be ultrasonic vibrations
Data Source
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AI summary
A method of operation is provided during which a tool (26) is arranged with a surface (25) of a component (22). The tool (26) includes a roller (42) contacting the surface (25). A rolling operation is performed on the surface (25) using the roller (42). A vibration operation is performed on the surface (25) through the roller (42) concurrently with the performing of the rolling operation.