Effect of Vibration Stress Relief on the Shape Stability of Aluminum Alloy 7075 Thin-Walled Parts

Gong, Hai; Sun, Ying; Liu, Yaoqiong; Wu, Yiping; He, Yanan; Sun, Xin; Zhang, Minghai

doi:10.3390/met9010027

Cited by 20 publications

(8 citation statements)

References 15 publications

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“…VSR is a supplement and development of TSR, replacing TSR within a certain range [18,19]. Many researchers [20][21][22][23] have studied the VSR during part resonance through experimental or numerical analysis. The larger amplitude generated by excitation can more effectively eliminate residual stress.…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Experiment of Stress Relief and Processing Deformation of 2219 Aluminum Alloy Ring

Dong

Gao

2023

Metals

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Large aluminum alloy ring forgings are the core components of heavy-duty rocket fuel storage tanks, and the large residual stress inside the rings leads to poor shape accuracy of large thin-walled parts. The initial stress of the 2219 aluminum alloy ring blank was tested using the drilling method, and the creep constitutive coefficient of the 2219 aluminum alloy was determined through stress relaxation tests. The numerical simulation processes of thermal stress relief (TSR), vibration stress relief (VSR), and thermal–vibration stress relief (TVSR) were compared and established. Through the correlation analysis between the actual measurement results of residual stress and the simulation results, it can be seen that the strong correlation in three directions at each measurement point accounts for over 37.5%, and the moderate correlation accounts for over 62.5%. This indicates that the numerical simulation model of 2219 aluminum alloy ring containing initial residual stress can accurately reflect the size and distribution of residual stress inside the actual ring. The simulation results show that the derived constitutive model can describe the stress relaxation process of TVSR by combining a single thermal time effect stress relaxation constitutive theory with a VSR plastic deformation material model. The simulation models established above were used to calculate the residual stress homogenization ability of three types of aging. The results showed that VSR, TSR, and TVSR can homogenize and reduce the residual stress field inside the ring, improve the distribution of residual stress inside the ring, and have a better overall homogenization ability of TVSR. The VSR control has a certain effect on reducing and homogenizing residual stress, but compared with TSR and TVSR, the reduction and homogenization ability of residual stress control is limited. The homogenization control effect TVSR > TSR > VSR, and the maximum equivalent stress homogenization rates of VSR, TSR, and TVSR are 52.8%, 80.6%, and 82.2%, respectively. Then, numerical simulation technology was used to study how the initial residual stress in the blank causes the deformation of the ring during the thin-walled machining process. The roundness error theory of the minimum containment area method was applied to evaluate the deformation degree during the thin-walled numerical machining process, and the TVSR method was used for stress regulation. The deformation law of the thin-walled machining of the ring under different aging parameters was studied.

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Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Experiment of Stress Relief and Processing Deformation of 2219 Aluminum Alloy Ring

Dong

Gao

2023

Metals

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show abstract

“…VSR is a supplement and development of TSR, replacing TSR within a certain range [15,16]. Many researchers [17][18][19][20][21] have studied the VSR during part resonance through experimental or numerical analysis. The larger amplitude generated by excitation can more effectively eliminate residual stress.…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Experiment of Stress Relief and Processing Deformation of 2219 Aluminum Alloy Ring

Li¹,

Dong²,

Ouyang³

et al. 2023

Preprint

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Large aluminum alloy ring forgings are the core components of heavy-duty rocket fuel storage tanks, and the large residual stress inside the rings leads to poor shape accuracy of large thin-walled parts. The initial stress of the 2219 aluminum alloy ring blank was tested using the drilling method, and the creep constitutive coefficient of the 2219 aluminum alloy was determined through stress relaxation tests. The numerical simulation processes of thermal stress relief (TSR), vibration stress relief (VSR), and thermal-vibration stress relief (TVSR) were compared and established. Through the correlation analysis between the actual measurement results of residual stress and the simulation results, it can be seen that the strong correlation in three directions at each measurement point accounts for over 37.5%, and the moderate correlation accounts for over 62.5%. This indicates that the numerical simulation model of 2219 aluminum alloy ring containing initial residual stress can accurately reflect the size and distribution of residual stress inside the actual ring. The simulation results show that the derived constitutive model can describe the stress relaxation process of TVSR by combining a single thermal time effect stress relaxation constitutive theory with a VSR plastic deformation material model. The simulation models established above were used to calculate the residual stress homogenization ability of three types of aging. The results showed that VSR, TSR, and TVSR can homogenize and reduce the residual stress field inside the ring, improve the distribution of residual stress inside the ring, and have a better overall homogenization ability of TVSR. The VSR control has a certain effect on reducing and homogenizing residual stress, but compared with TSR and TVSR, the reduction and homogenization ability of residual stress control is limited. The homogenization control effect TVSR>TSR>VSR, and the maximum equivalent stress homogenization rates of VSR, TSR, and TVSR are 52.8%, 80.6%, and 82.2%, respectively. Then, numerical simulation technology is used to study how the initial residual stress in the blank will cause the deformation of the ring during the thin-walled machining process. The roundness error theory of the minimum containment area method is applied to evaluate the deformation degree during the thin-walled numerical machining process, and the TVSR method is used for stress regulation. The deformation law of the thin-walled machining of the ring under different aging parameters is studied.

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“…In VSR, cyclic external loads are applied to the workpieces with residual stress for a certain length of time, and this process is believed to cause microplastic deformation in micro regions of the workpieces and lead to the relaxation of residual stress [8][9]. This technology has been successfully implemented in the manufacturing of many important workpieces, such as welded shafts, marine shafts, large rails, large surface plates from stainless steel, and thin parts from aluminum alloy [10][11][12][13].…”

Section: Introductionmentioning

confidence: 99%

Effects of the Vibration Amplitude in Vibratory Stress Relief on the Fatigue Life of Structures

Manh¹,

Van²,

Van³

et al. 2021

Adv. technol. innov.

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This research aims to investigate the effects of vibration amplitude in vibratory stress relief (VSR) on the fatigue strength of structures with residual stress. Experiments are carried out on specimens with residual stress generated by local heating. Flat specimens made of A36 steel are prepared to be suitable for setting up fatigue bending tests on a vibrating table. Several groups of samples are subjected to VSR at resonant frequencies with different acceleration amplitudes. The results show that VSR has an important influence on the residual stress and fatigue limit of steel specimens. The maximum residual stress in the samples is reduced about 73% when the amplitude of vibration acceleration is 57 m/s2. The VSR method can also improve the fatigue limit by up to 14% for steel samples with residual stress.

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Effect of Vibration Stress Relief on the Shape Stability of Aluminum Alloy 7075 Thin-Walled Parts

Cited by 20 publications

References 15 publications

Numerical Simulation and Experiment of Stress Relief and Processing Deformation of 2219 Aluminum Alloy Ring

Numerical Simulation and Experiment of Stress Relief and Processing Deformation of 2219 Aluminum Alloy Ring

Numerical Simulation and Experiment of Stress Relief and Processing Deformation of 2219 Aluminum Alloy Ring

Effects of the Vibration Amplitude in Vibratory Stress Relief on the Fatigue Life of Structures

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