DOI: https://doi.org/10.15587/1729-4061.2019.163697

Definition of energy efficient law of mechanical impact in vibratory stress relief of metal parts

Oleksii Sheremet, Mykola Ivchenkov, Olena Ivchenkova, Kateryna Sheremet

Abstract


The study is based on the method of vibratory stress relief, which is used to reduce the residual stresses in cast and welded parts, and is an alternative to thermal deformation methods, because it is unpretentious to the mass, shape and dimensions of the part.

Vibratory stress relief is usually carried out using unbalance electromechanical systems, which are simple in design of the power section and control system. In such systems, processing occurs simultaneously at only one resonant frequency. The workpiece, as a rule, is characterized by several resonant frequencies that have a tendency to shift to the low-frequency region during the implementation of the vibration effect. The technological process of sequential processing at each variable resonant frequency is rather time-consuming and not efficient in terms of the cost of electrical energy. In order to reduce the cost of time and energy, this study proposes the use of the most advanced processing methods at several resonant frequencies. Based on the algorithms of sequential vibratory stress relief at several resonant frequencies of the part and their changes towards low ones, it was proposed to carry out processing by a polyharmonic perturbing force in a limited frequency band. This effect has a bandwidth that contains all the possible frequencies of the part where vibratory stress relief occurs. Such an effect can be realized with the help of an electrodynamic linear motor as an executive body. The advantage of an electrodynamic linear motor is the proportionality of the generated force to the current supplied to the moving conductor and its repetition in form.

By means of mathematical modeling for the selected example, it was found that narrowing the frequency range in the low-frequency region by 5 times reduces energy costs by more than 4,000 times as compared with the broadband law of mechanical action on a part. A theoretically determined energy-efficient law can be software-implemented in control systems for electrodynamic linear motors that implement vibratory stress relief

Keywords


vibratory stress relief; resonant frequency; energy efficient law; amplitude spectrum; electrodynamic linear motor

References


Withers, P. J. (2007). Residual stress and its role in failure. Reports on Progress in Physics, 70 (12), 2211–2264. doi: https://doi.org/10.1088/0034-4885/70/12/r04

Schajer, G. S. (2010). Relaxation Methods for Measuring Residual Stresses: Techniques and Opportunities. Experimental Mechanics, 50 (8), 1117–1127. doi: https://doi.org/10.1007/s11340-010-9386-7

Radchenko, V. P., Bochkova, T. I., Tsvetkov, V. V. (2015). Residual stresses relaxation in surface-hardened half-space under creep conditions. Vestn. Samar. Gos. Tekhn. Univ., Ser. Fiz.-Mat. Nauki [J. Samara State Tech. Univ., Ser. Phys. Math. Sci.], 19 (3), 504–522. doi: https://doi.org/10.14498/vsgtu1428

Walker, C. (2011). A theoretical review of the operation of vibratory stress relief with particular reference to the stabilization of large-scale fabrications. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, 225 (3), 195–204. doi: https://doi.org/10.1177/0954420711402877

Wang, J.-S., Hsieh, C.-C., Lai, H.-H., Kuo, C.-W., Wu, P. T.-Y., Wu, W. (2015). The relationships between residual stress relaxation and texture development in AZ31 Mg alloys via the vibratory stress relief technique. Materials Characterization, 99, 248–253. doi: https://doi.org/10.1016/j.matchar.2014.09.019

Wang, Y., Kramer, M. S. (2018). Pat. No. US9863030B2. Stress relief of mechanically roughened cylinder bores for reduced cracking tendency. Available at: https://patents.justia.com/patent/9863030

Zhao, X., Zhang, N., Wang, A. (2018). Modeling and Simulation Technology of High Frequency Vibratory Stress Relief Treatment for Complex Thin -Walled Workpiece. MATEC Web of Conferences, 206, 04001. doi: https://doi.org/10.1051/matecconf/201820604001

Vukojevic, N., Hadžikadunić, F. (2012). Experiences of application of vibratory residual stress relieving methodology on large welded constructions. Conference: COMETa 2012 – 1st International Scientific Conference on Mechanical Engineering Technologies and Applications, At BiH, 229–234.

Hsieh, C.-C., Wang, P.-S., Wang, J.-S., Wu, W. (2014). Evolution of Microstructure and Residual Stress under Various Vibration Modes in 304 Stainless Steel Welds. The Scientific World Journal, 2014, 1–9. doi: https://doi.org/10.1155/2014/895790

Simakov, G. M., Topovskiy, V. V. (2016). Dynamic modes of electromechanical unbalance vibration exciter with induction motor under vector control. 2016 13th International Scientific-Technical Conference on Actual Problems of Electronics Instrument Engineering (APEIE). doi: https://doi.org/10.1109/apeie.2016.7807065

Lashchenko, G. I. (2016). Tekhnologicheskie vozmozhnosti vibracionnoy obrabotki svarnyh konstrukciy (Obzor). Avtomaticheskaya svarka, 7, 28–34.


GOST Style Citations


Withers P. J. Residual stress and its role in failure // Reports on Progress in Physics. 2007. Vol. 70, Issue 12. P. 2211–2264. doi: https://doi.org/10.1088/0034-4885/70/12/r04 

Schajer G. S. Relaxation Methods for Measuring Residual Stresses: Techniques and Opportunities // Experimental Mechanics. 2010. Vol. 50, Issue 8. P. 1117–1127. doi: https://doi.org/10.1007/s11340-010-9386-7 

Radchenko V. P., Bochkova T. I., Tsvetkov V. V. Residual stresses relaxation in surface-hardened half-space under creep conditions // Vestn. Samar. Gos. Tekhn. Univ., Ser. Fiz.-Mat. Nauki [J. Samara State Tech. Univ., Ser. Phys. Math. Sci.]. 2015. Vol. 19, Issue 3. P. 504–522. doi: https://doi.org/10.14498/vsgtu1428 

Walker C. A theoretical review of the operation of vibratory stress relief with particular reference to the stabilization of large-scale fabrications // Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications. 2011. Vol. 225, Issue 3. P. 195–204. doi: https://doi.org/10.1177/0954420711402877 

The relationships between residual stress relaxation and texture development in AZ31 Mg alloys via the vibratory stress relief technique / Wang J.-S., Hsieh C.-C., Lai H.-H., Kuo C.-W., Wu P. T.-Y., Wu W. // Materials Characterization. 2015. Vol. 99. P. 248–253. doi: https://doi.org/10.1016/j.matchar.2014.09.019 

Wang Y., Kramer M. S. Stress relief of mechanically roughened cylinder bores for reduced cracking tendency: Pat. No. US9863030B2. 2018. URL: https://patents.justia.com/patent/9863030

Zhao X., Zhang N., Wang A. Modeling and Simulation Technology of High Frequency Vibratory Stress Relief Treatment for Complex Thin -Walled Workpiece // MATEC Web of Conferences. 2018. Vol. 206. P. 04001. doi: https://doi.org/10.1051/matecconf/201820604001 

Vukojevic N., Hadžikadunić F. Experiences of application of vibratory residual stress relieving methodology on large welded constructions // Conference: COMETa 2012 – 1st International Scientific Conference on Mechanical Engineering Technologies and Applications, At BiH. 2012. P. 229–234.

Evolution of Microstructure and Residual Stress under Various Vibration Modes in 304 Stainless Steel Welds / Hsieh C.-C., Wang P.-S., Wang J.-S., Wu W. // The Scientific World Journal. 2014. Vol. 2014. P. 1–9. doi: https://doi.org/10.1155/2014/895790 

Simakov G. M., Topovskiy V. V. Dynamic modes of electromechanical unbalance vibration exciter with induction motor under vector control // 2016 13th International Scientific-Technical Conference on Actual Problems of Electronics Instrument Engineering (APEIE). 2016. doi: https://doi.org/10.1109/apeie.2016.7807065 

Lashchenko G. I. Tekhnologicheskie vozmozhnosti vibracionnoy obrabotki svarnyh konstrukciy (Obzor) // Avtomaticheskaya svarka. 2016. Issue 7. P. 28–34.







Copyright (c) 2019 Oleksii Sheremet, Mykola Ivchenkov, Olena Ivchenkova, Kateryna Sheremet

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ISSN (print) 1729-3774, ISSN (on-line) 1729-4061