RESIDUAL STRESS MANAGEMENT
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RSM TM is an important component in the processes of DESIGN, MANUFACTURING, MAINTENANCE and PowerPoint PPT Presentation


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RESIDUAL STRESS MANAGEMENT. RSM TM is an important component in the processes of DESIGN, MANUFACTURING, MAINTENANCE and REPAIR of PARTS and WELDED ELEMENTS. IMPORTANCE OF RESIDUAL STRESS MANAGEMENT. RESIDUAL STRESSES ORIGINATE FROM:

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RSM TM is an important component in the processes of DESIGN, MANUFACTURING, MAINTENANCE and

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Rsm tm is an important component in the processes of design manufacturing maintenance and

RESIDUAL STRESS MANAGEMENT

RSMTMis an important component in the processes of

DESIGN,

MANUFACTURING,

MAINTENANCE and

REPAIR of PARTS and WELDED ELEMENTS


Importance of residual stress management

IMPORTANCE OF RESIDUAL STRESS MANAGEMENT

RESIDUAL STRESSES ORIGINATE FROM:

  • Differential plastic flow Differential cooling rates

  • Phase transformations with volume changes etc.

    RESIDUAL STRESSES ARE CREATED BY:

  • Welding Machining Forging

  • Rolling Surface treatments Casting Heat treatment

    WHERE RESIDUAL STRESSES ARE IMPORTANT:

  • Fatigue Life Corrosion Resistance

  • Dimensional Stability Brittle Fracture

  • Distortion


Rsm tm is an important component in the processes of design manufacturing maintenance and

STAGES IN RESIDUAL STRESS (RS) MANAGEMENT

Stage 1:RS Determination

  • MEASUREMENT: Destructive, Non-Destructive

  • COMPUTATION

    Stage 2:RS Effect Analysis

  • EXPERIMENTAL STUDIES

  • COMPUTATION

    Stage 3:RS Modification (if required)

  • CHANGES in TECHNOLOGY of MANUFACTORING / ASSEMBLY

  • APPLICATION of STRESS - RELIEVING TECHNIQUES


Rsm tm is an important component in the processes of design manufacturing maintenance and

RESIDUAL STRESS MANAGEMENT

Proposed Complex of Advanced Engineering Tools

Stage 1: RS Determination

Ultrasonic Measurement of Applied and Residual Stresses

Device and Software – UltraMARSTM

Stage 2: RS Effect Analysis

Expert System for Fatigue Assessment and Optimization

of Parts and Welded Elements - RESIsTTM

Stage 3: RS Modification (if required)

Ultrasonic Peening of Parts and Welded Elements

Equipment and Software – UltraPeenTM


Rsm tm is an important component in the processes of design manufacturing maintenance and

RESIDUAL STRESS MANAGEMENT

Ultrasonic Measurement of Applied and Residual Stresses

Computerized complex - UltraMARSTM

Laptop

Measurement Unit

  • Expert System for Residual Stress Analysis

  • Advanced database and analysis of the influence of residual stresses on the fatigue life of parts and welded elements

  • Measurement Unit with Transducers

  • Supporting Software


Rsm tm is an important component in the processes of design manufacturing maintenance and

RESIDUAL STRESS MANAGEMENT

Expert Systemfor Fatigue Assessment and Optimizationof Parts and Welded Elements RESIsTTM

The RESIsTTMis an Expert System for optimization of welded elements and structures by fatigue criterion. The following important parameters of welded structures with the goal to enhance the fatigue performance are analyzed:

 preferred design of parts and welded elements;

 material selection;

 welding and other technological processes;

 residual stresses;

 application of improvement treatments;

 influence of possible repair technologies;

 realistic service conditions.


Rsm tm is an important component in the processes of design manufacturing maintenance and

RESIDUAL STRESS MANAGEMENT

Ultrasonic Peening of Parts and Welded Elements

Ultrasonic Transducer and Generator

Software

● Piezoelectric transducer with a set of

heads for different applications:

weight: ~2 kg, length: ~420 mm

 ● Ultrasonic generator:

weight: ~ 4.5 kg

dimensions: 350x250x90 mm

 ● Output frequency: 20 kHz

 ● Power supply: 250 – 500 watts

● Optimization of the UP application parameters: maximum possible increase in fatigue life of parts and welded elements with minimum cost, labor- and power-consumption 

● Quality monitoring of UP process

● Fatigue assessment of welded elements after UP


Rsm tm is an important component in the processes of design manufacturing maintenance and

RESIDUAL STRESS MANAGEMENT

Measurement of Residual Stresses, Fatigue Assessment and Improvement Treatment of Welded ElementResult: 4 times increase in fatigue life

Fatigue curves of fillet welded joint

Distribution of residual stresses

1 - r = 240 MPa (Δ = 85 MPa);

2 - r = -10 MPa (Δ = 123 MPa);

3 - r = 40 MPa;4 - r = -60 MPa

1 and 2 - before and after application

of the improvement treatment


Interaction of software and hardware

INTERACTION OF SOFTWARE AND HARDWARE

SOFTWARE ULTRAPEEN

UP Optimum Application and Remote Control

EXPERT SYSTEM RESIST

Fatigue Assessment

And Optimization of

Welded Elements

SOFTWARE ULTRAMARS

Advanced Database and

Residual Stress Analysis

DEVICE ULTRAPEEN

Ultrasonic Peening of

Parts and Welded

Elements

DEVICE ULTRAMARS

Ultrasonic Measurement

Of Applied and Residual

Stresses

WELDED

ELEMENTS

WELDED ELEMENTS

with Enhanced Fatigue Performance,

Corrosion Resistance, Dimensional Stability

and Reduced Distortions


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