Practical aspects of Vibratory Stress Relieving

Romul Chiorean
Galaxy srl, str.Clujului nr.98, Teius e-mail: [email protected]

Abstract
We present some of achievements on Vibratory Stress Relief, one of most controversial no-conventional technology. We have invented a new method and equipment for VSR and we patented this since 1983. An important number of workpiece was treated by this technology and a know-how was developed. The equipment was updated and redesigned based on latest achievements of electronics, computers and IT. Our method was compared with most known devices and the most limitations of VSR was established.

Keywords: stress relief, vibration, application, analysis

Introduction
Speaking about VSR (Vibratory Stress Relieving) always is a challenge. Why? Because it is a very controversial subject even as related in the 1943 paper by Saunders and McGoldrick, published in the Journal of American Society of Naval Engineers, Vol. 55, No. 4, pgs. 589-609, the US Navy used vibratory stress relief to stabilize a variety of components, especially large jigs and fixtures used in shipyards. The new technical challenges, the contemporary crisis, the theoretical, experimental and applied research work put this no-conventionally technology in a new light. Our research on the field start 30 years ago and we open a new way in VSR process evaluating with our method [1]. Our principle (VSR evaluation by spectrum analysis) was adopted as-is or modified by a lot of VSR equipment producers and it is the basic element of Chinese standard JB/T 5926-91 on VSR [13].

Our practical and applied knowledge

Until 1990, we were focused on: - to demonstrate the correctness of our solution, - to achieve an industrial Romanian equipment, - to apply the our new patented technology for a large variety of workpieces, - to establish the limitations of VSR technology. To achieve all this, we had a very close and special cooperation with the most significant Romanian research institutes and universities like ICCEM, ICPTT, ICPTCM, Polytechnical Institute of Cluj-Napoca, Polytechnical Institute of Bucharest, University of Craiova, University

of Iassy. Our special gratitude to regretted Dumitru Remus Mocanu, Prof.Dr.Doc.Eng. who lead us and managed the check tests to prove the efficiency of our invention to be patented. In cooperation with Polytechnical Institute of Cluj-Napoca and ITC Cluj-Napoca we achieved one industrial model and a homologated prototype of VSR equipment named IDV-287 [9], [10] and [11], and a model of device to be developed EGAVIB-1 [12]. On the usability of VSR as alternative of Thermal Stress Relief and the limits of this usability, we checked a large variety on materials (all the usual industrial metals) and pieces from few grams (hardened steel munitions for weapons) to tens of tones (welded steel assemblies). The most spectacular result was obtained for workpieces with high dimensional stability and tolerances exigency, unable to be solved by TSR, surface treated workpieces and large size welded assemblies. Our method can be used very well also like a qualitative nondestructive testing method if a part or structure is well thermal treated or no. On the limitations of VSR, we observed that generally, the workpieces or components that have had their physical properties extensively altered by cold working or tempering, or have been through hardened resists VSR. Even within this category of borderline candidates, however, there are exceptions which can make the use of vibratory stress relief a viable alternative to heat treating. In the case of aluminum weldments, for example, even if the weldments components are of a highly tempered metal, the weldment remains a candidate for treatment. Since 1990, our goal was to update, to redesign the equipment according the new achievements especially on electronics, computers and IT. Also, we were focused on comparing the most known usual VSR equipments to observe the differences and to find the specific range of application of each model. We were able to compare our ancient equipment, our new equipment, Meta-Lax and TX-VSR in real industrial conditions. Also, in a technical cooperation with an European representative of Meta-Lax we checked our new VSR evaluating software and device by verifying it for a MetaLax process in real conditions in a Hungarian factory. More then that, our discussion with Chinese TX-VSR and Navigator manufacturers emphasized the correctness of our way. Since 2006, we applied our method for hundreds of welded steel components and assemblies from tens kilos to tons with a large field of sizes, components included in huge machine-tools manufactured by an important international company. It is obvious that this company checked our technology and our VSR treatment according to all their rules and demands and we were accepted as VSR services provider. A VSR on site working point and some components are shown in Fig.1.

Fig. 1 On site VSR working point and some components to be treated

On site, we verified accidentally the result of our VSR treatment by cracking an auxiliary element and observing the dimensional stability as shown in Fig.2.

Fig. 2 Auxiliary elements broken after VSR (left) and the component (right)

In Fig.3 is illustrated the evidence of spectrum changes during the VSR process for two identical welded components, one cold and other treated few time after last welding (warm).

Fig. 3 Spectrums of cold (top) and warm (down) of two identical components

A major spectrum changes is shown in Fig.4.

Fig. 4 A major spectrum changes

Usually, for most cases, tree spectrums are enough to describe the VSR process. The shape of spectrums can be very different from a workpiece to an other workpiece and depends of many variable factors. A very important feature of our VSR method is that we compare always the spectrums obtained in the same constant process conditions (parameters), the unique variable being the residual stress. Fig. 5 shows the changes of spectrums step by step, from initial to intermediate and to final.

Fig. 5 The spectrum changes from initial to intermediate (top), initial to final, intermediate to final and all the tree spectrums in a diagram (bottom)

By analyzing the evolution of spectrum changes we observe that in most cases the important changes occur in the first part of VSR process, but we can not exclude important changes especially when big or large components are treated. Such situation occurs also when a large workpiece is treated by moving the vibrators fixture during the process.

In Fig.6 is illustrated our evaluation of a Meta-Lax VSR treatment in a Hungarian factory.

Fig. 6 Evaluation of Meta-Lax VSR treatment; our laptop with spectrum analyzer software (bottom)

Fig.7 shows the intermediate and the final spectrums of the upper Meta-Lax VSR treatment.

Fig. 7 The intermediate and final spectrums of Meta-Lax VSR treatment shown on Fig.6

The characteristics of spectrums changes for welded workpiece shown on Fig.6 is that the piece is very rigid and vibrate only on low frequencies. The acceleration is depending very close on induced force. A very important feature of our method is that we can use the information revealed by the spectrums as a NDT (Non Destructive Technology). Few years ago we found in a lot of identical large workpieces one with a very different shape of spectrum. Very curious, we have investigated the cause and we have found that the different workpiece was assembled in mirror because of error of assembling team.

Conclusions
After a deep analysis of known VSR patents and equipments, we can say that our invention was really revolutionary and our principles are used on modern VSR equipments and standards. Our VSR process evaluation method based on spectrum analysis is used now on German and American equipments [17] and as variant on Chinese VSR standard [13]. By analyzing the behaviour of treated components, we concluded that a most important kind of welded steel parts and assemblies are suitable for VSR treatment but it is very important that the technologist must cooperate with VSR specialist to establish the best way of manufacturing. VSR can not replace TSR in few cases because PWHT (Postweld Heat Treatment) does more
than relieve stress. [18]

The most resistant to VSR treatment are the very rigid components, especially the components with high deformed elements. We recommend is such cases a TSR for the high deformed element or an accurate PWHT. We can observe also that the spectrum changes for cold piece is more important compared to the warm piece. For each piece we recommend tree spectrums, initial, intermediate and final sweep. The spectrum analysis method can be used together with all known VSR equipments and it is possible to optimise all the VSR process including the sensitive frequencies and the treatment duration. Now the duration is based on experience. For large components or assemblies we recommend using two vibration exciters simultaneously to reduce the time and using better the vibration energy. TX-VSR equipment provide a larger frequency range but its power decrease for lower frequencies. Other equipments based on classical eccentric vibrator are limited on frequency range but they are efficient enough to low frequencies too. Many important companies reconsider this technology like a real money, time and medium protective alternative to the Thermal (Heat) Stress Relief and are looking for implementation on their manufacturing lines [16].

References
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Aspecte practice ale Detensionarii prin Vibratii

Rezumat
Prezentam cateva dintre realizarile noastre in domeniul DV (Detensionarii prin Vibratii), una dintre cele mai controversate tehnologii neconventionale. Am inventat o noua metoda si un nou echipament pentru DV si le-am brevetat inca din 1983. Un important numar de piese au fost tratate cu aceasta tehnologie si am dezvoltat un know-how. Echipamentul a fost reactualizat si reproiectat pe baza ultimelor realizari in electronica, calculatoare si IT. S-a comparat metoda noastra cu cele mai cunoscute echipamente si s-au stabilit cele mai multe restrictii ale utilizarii DV.