Vibro-treating Apparatus for Uniform Surface Treatment
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Solution Overview
Problem
Current vibro-treating processes, such as vibropolishing and shot peening, face inefficiencies in treating large numbers of small objects due to fixed processes that require extensive setup and processing time, and vibropeening suffers from uneven surface treatment distribution within the container.
Innovation Solution
A method and apparatus that control the relative displacement between vibro-treating media and the object's surface area to provide a uniform vibro-treating effect by adjusting the object's vertical movement within and out of the media, ensuring even compressive residual stress and surface refinement across the entire surface, with pre-determined conditions optimizing treatment time and intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed process with fixture is used to hold and treat objects, then manufacturing precision is maintained, but productivity decreases due to extensive setup and processing time
Solution Approach 1:
The patent implements dynamic positioning of objects within the vibro-treating container, allowing objects to be moved to optimal treatment positions during the process. This dynamic adjustment enables uniform surface treatment while reducing processing time, as objects can be treated in their natural positions without extensive fixture setup and removal operations
Solution Approach 2:
The system is designed to treat multiple objects of different sizes and shapes simultaneously in a single container, eliminating the need for dedicated fixtures for each object type. This multi-functional approach maintains treatment precision while dramatically improving productivity by processing batches of objects without repeated setup
2Strength
If vibropeening is used to treat objects, then compressive residual stress is imparted, but surface treatment uniformity deteriorates due to disproportionate effects in different areas
Solution Approach 1:
The patent segments the treatment process into controlled phases with specific container orientations and vibration parameters. By dividing the treatment into stages with different media depths and agitation intensities, uniform compressive residual stress is achieved across all surface areas, eliminating the disproportionate effects seen in conventional single-stage vibropeening
Solution Approach 2:
The system dynamically changes treatment parameters including vibration frequency, amplitude, and media depth during the process. These parameter variations ensure that all areas of the object receive equivalent treatment intensity, producing uniform compressive residual stress distribution while maintaining the strength benefits of vibropeening
3Strength
If traditional shot peening is used to impart compressive residual stress, then strength is improved, but surface roughness increases requiring additional finishing operations
Solution Approach 1:
The patent merges shot peening and vibropolishing into a single integrated process. The same vibro-treating system performs both functions sequentially or simultaneously, imparting compressive residual stress while concurrently smoothing the surface. This combination eliminates the need for separate finishing operations, maintaining strength improvement while achieving the desired surface finish quality
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 enables efficient and uniform treatment of objects, reducing processing time and ensuring consistent surface quality by ensuring all areas receive intense vibro-treating conditions, improving surface roughness and edge features, and accommodating various object sizes and shapes.
Implementation Method 1
controlling a relative displacement between a vibro-treating media and a surface area of the object to provide a vibro-treating effect, the vibro-treating effect comprising imparting a layer of compressive residual stress onto the surface area of the object
Implementation Method 2
vibropeening employs the inertia of heavier media to impart the required compressive residual stress onto the fan blade or aerofoil whilst concurrently smoothing the object and/or bringing about a material removal
Implementation Method 3
controlling substantially vertical movement of the object relative to a surface of the vibro-treating media whilst controlling the relative displacement between the vibro-treating media and the surface area of the object
Implementation Method 4
the media rubs exposed areas of the object, causing a localised material removal from the tips of any outwardly extending asperities, so smoothing the surface of the object
Data Source
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AI summary
A method and apparatus (23) for vibro-treating an object (30). The method comprises the steps of controlling a relative displacement between a vibro-treating media (32) and a surface area of the object (30) to provide a vibro-treating effect; and, controlling movement of the object (30) relative to a surface of the vibro-treating media (32) whilst controlling relative displacement between the vibro-treating media (32) and the surface area of the object (30), according to one or more pre-determined conditions, to provide a substantially even vibro-treating condition over the surface area of the object (30).