rsm tm is an important component in the processes of design, manufacturing, maintenance and
DESCRIPTION
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: - PowerPoint PPT PresentationTRANSCRIPT
RSMTM is an important component in the processes of
DESIGN, MANUFACTURING, MAINTENANCE and REPAIR of PARTS and WELDED ELEMENTS
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
STAGES IN RESIDUAL STRESS (RS) STAGES IN RESIDUAL STRESS (RS) MANAGEMENTMANAGEMENT
Stage 1:Stage 1: RS DeterminationRS Determination• MEASUREMENT: Destructive, Non-Destructive
• COMPUTATION
Stage 2:Stage 2: RS Effect AnalysisRS Effect Analysis • EXPERIMENTAL STUDIES
• COMPUTATION
Stage 3:Stage 3: RS Modification (if required)RS Modification (if required)• CHANGES in TECHNOLOGY of MANUFACTORING / ASSEMBLY
• APPLICATION of STRESS - RELIEVING TECHNIQUES
RESIDUAL STRESS MANAGEMENTRESIDUAL STRESS MANAGEMENTProposed Complex of Advanced Engineering ToolsProposed Complex of Advanced Engineering Tools
Stage 1: Stage 1: RS DeterminationRS Determination
Ultrasonic Measurement of Applied and Residual Stresses
Device and Software – UltraMARSTM
Stage 2: Stage 2: RS Effect AnalysisRS Effect Analysis
Expert System for Fatigue Assessment and Optimization
of Parts and Welded Elements - RESIsTTM
Stage 3: RS Modification (if required)Stage 3: RS Modification (if required) Ultrasonic Peening of Parts and Welded Elements
Equipment and Software – UltraPeenTM
RESIDUAL STRESS MANAGEMENTUltrasonic Measurement of Applied and Residual Stresses
Measurement Unit Laptop
•Measurement Unit with Transducers•Supporting Software
• 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
Computerized complex - UltraMARSTM
RESIDUAL STRESS MANAGEMENTExpert SystemExpert System for for Fatigue AssessmentFatigue Assessment and and OptimizationOptimization of Parts of Parts
and Welded Elements and Welded Elements RESIsTRESIsTTMTM
The RESIsTTM is 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.
RESIDUAL STRESS MANAGEMENT
UltraUltrasonic sonic PeenPeening of Parts and Welded Elements ing of Parts and Welded Elements
● 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
Ultrasonic Transducer and Generator
● 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
Software
RESIDUAL STRESS MANAGEMENT
Distribution of residual stresses
1 and 2 - before and after application of the improvement treatment
Fatigue curves of fillet welded joint
1 - r = 240 MPa (Δ = 85 MPa);2 - r = -10 MPa (Δ = 123 MPa);3 - r = 40 MPa; 4 - r = -60 MPa
Measurement of Residual Stresses, Fatigue Assessment and Measurement of Residual Stresses, Fatigue Assessment and Improvement Treatment of Welded ElementImprovement Treatment of Welded Element
Result: 4 times increase in fatigue lifeResult: 4 times increase in fatigue life
INTERACTION OF SOFTWARE AND HARDWARE
SOFTWARE ULTRAPEEN
UP Optimum Application and Remote Control
SOFTWARE ULTRAMARS
Advanced Database and Residual Stress Analysis
EXPERT SYSTEM RESIST
Fatigue AssessmentAnd Optimization of
Welded Elements
WELDED ELEMENTS
DEVICE ULTRAPEENUltrasonic Peening of
Parts and WeldedElements
DEVICE ULTRAMARSUltrasonic MeasurementOf Applied and Residual
Stresses
WELDED ELEMENTSwith Enhanced Fatigue Performance,
Corrosion Resistance, Dimensional Stabilityand Reduced Distortions