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INSTRUCTION MANUAL
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MANUFACTURED BY SAHYOG ENTERPRISE TARUN PLASTIC COMPOUND, MOGRA VILLAGE ROAD, ANDHERI (EAST),MUMBAI 400 069 PH: (022) 28200559, 26840346 Email : flextool@gmail.com
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GLOSSORY OF TERMS
Accelerometer It is a small sensor, which senses the vibration acceleration and converts the signal into electrical signal. Amplitude is the peak-to-peak displacement of the work piece during vibration. Damping is the loss of vibration energy due to natural or forced friction, like contact with floor. Frequency The numbers of vibrations per second of a vibrating body. g Acceleration due to gravity, 9.81 m/sec2 Mode The pattern of vibration of a component. Node A still area or a line on a vibrating component. Resonance It is the condition of maximum response. It arises when the forced frequency of vibration is equal to the natural frequency of the work piece.
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INTRODUCTION
It is found and universally accepted that residual stresses in a metal are the main cause of dimensional instability. Residual stresses are mainly developed in a component due to: 1. Differential cooling of the component 2. Cold deformation 3. Phase transformation The residual stresses are the main cause of the dimensional instability of the component. Residual stresses are hard to visualize, difficult to measure and extremely difficult to calculate and predict. To achieve the dimensional stability it is required to redistribute or reduce the residual stress level in the component. This can be achieved mainly by three different methods: Natural aging Thermal Stress Relieving Vibratory Stress Relieving All the processes have their merits and demerits over each other. While natural aging does not require any equipment for stress relieving, it is a very long time consuming process, almost of the order of 8 to 12 months and hence the indirect cost involved is much higher compared to other two processes. Thermal Stress Relieving (TSR) requires a very large capital expenditure and also it has a limitation by the volume of the furnace to handle the job. The treatment cycle in TSR process is very long and is associated with very high consumption of energy. Vibratory Stress Relieving (VSR) brings the dimensional stability by vibrating the component at its natural frequency. Because of the simplicity of the process it has become widely popular over last decade.
STREL-Q The major advantages of VSR process are: Very short treatment cycle compared to other two processes. High energy saving. Very less material handling charges, as the process goes to the work piece.
However it should be noted that the VSR process is not the direct replacement of the TSR process in certain applications. It has its own limitations, which we shall discuss in the chapters to come.
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PRINCIPLE OF VSR
Any Stress relaxation is associated with the plastic deformation of the stressed atoms inside the component. In VSR method the cyclic loading is applied to the work piece by using the vibrator. These injected stresses are supper imposed on the existing residual stresses. The resultant stress value crosses the yield point of the component and it will undergo micro plastic deformation. With series of micro plastic deformation the stress reduction is achieved which in turn stabilizes the component to achieve dimensional stability. The interesting feature of cyclic sinusoidal loading is that the Stress-Strain curve takes the different shape than the original shape, and hence the resultant yield stress comes down drastically and hence the stress relaxation is achieved at very low energy consumption.
APPLICABILITY OF VSR
Generally in the following areas the VSR technique is applicable: A wide variety of cast iron and mild steel welded structure. Low alloys high strength structures. Stainless steel cast and welded structures. Almost all structures where the stresses have been induced due to differential cooling pattern during manufacturing. VSR has got limited applications in following areas: Severely cold deformed sections like cold rolled, drowned, or strain hardened materials. Precipitation hardenable material. Stresses generated due to heat treatment for example heattreated hardened material. It should be noted that VSR does not change the metallurgy of the material hence code does not permit pressure vessel, pipe work etc to be treated by VSR method. The change in metallurgy is required for corrosion or high-pressure problems in pipe work and pressure vessels. Hence it is recommended that the thermal stress relieving be carried out for these applications.
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STREL-Q device. With this we can have a closed loop control over the entire VSR process. The accelerometer along with its cable is a very sensitive and costly element and should be handled very carefully during the process. The strip chart recorder (Fig 1,part 7) is a device, which can be utilized if the hard copy of the entire VSR process is required. It plots the displacement v/s time during the VSR process. It is a useful device for the validation process or to compare the previous data for similar jobs.
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OPERATING INSTRUCTIONS
The following instructions should generally be followed for operating the VSR Equipment: 1. Observe the work piece thoroughly for cracks. There should not be any crack on the work piece. 2. Mount the Exciter on the work piece, at the convenient place and hold it rigidly with the clamps. See supporting the component and fixing the vibrator on page 11 3. Place the isolators below the work piece so that the work piece is in balanced condition. 4. Give 220V, 1ph. Electric connection at single-phase socket input at the back panel (Fig 1,part 12), Three phase output (Fig 1,part 11) to Exciter and the sensor cable at sensor terminal (fig 1,part 13). The other end of sensor cable is connected to the accelerometer sensor. 5. Mount the accelerometer on a clean flat surface over the work piece. Handle it very carefully; mount it using the permanent Magnet provided with the sensor, or with any other means. 6. Start the process, put ON the mains switch (fig 1,part 4). The well come screen will appear on the monitor ( Fig 1, part 3). Wait for few seconds, the well come screen will change and the equipment will enter into the Manual mode, Screen 2 of Annexure 1 will appear. 7. Press the START button (on the touch screen), Screen 3 of Annexure 1 will appear and Indicator lamp (Fig 1, Part 10) will glow indicating the start of process. The Indicator lamp will not glow if the sensor is open or Emergency switch (Fig 1, Part 8) is pressed. To activate the process timer press the TIMER MODE SELECT BUTTON on the screen. Set the TOTAL RUN TIME in minutes. We recommend setting the timer to about 15 minutes. Put ON the Chart recorder (fig1, part 9) to take out the process Time v/s Amplitude graph. The VSR operation is carried as follows: a) Sweep the frequency knob (fig1, part 1) of frequency indicator from minimum to maximum slowly, while observing the vibration meter simultaneously. Try to locate the resonant frequencies (the resonant frequency and its harmonics). The resonant frequency is located when the maximum displacement is indicated on the analogue resonance meter. The harmonics are located beyond the Sahyog Enterprise, Bombay 400 069. 8
STREL-Q resonant frequency by locating, once again, the displacement peak during the sweep. If the resonance deflection is very small, change the RANGE switch (fig1, part 5) in position 1. If deflection is out of range change the RANGE switch in next higher position i.e. 2 or 3 for better readability. Run the vibrator at all the selected resonant frequencies. The minimum time duration for effective VSR treatment should be 5000 cycles for CI or MS fabricated jobs. For example, if the resonance found at 25 Hz. The process time would be 5000/25 i.e. 200 seconds. If the vibrations are applied for longer duration nothing wrong will happen to the job. During the process take out the recorded chart from the strip chart recorder. Refer the chart recorder manual supplied separately. Repeat the entire process with the different position of the vibrator (generally 90 degree to previous position.) To terminate the VSR process at any stage, press EMERGENCY (Fig 1 , Part 8) button.
b)
c)
d) e)
Following are the few thumb rules of VSR techniques and should generally be followed during the process if possible: (a) Vibration isolators should be placed below the job so that the job is in balanced condition. Wooden planks, Rubbers or tyres may be used as isolators. For small jobs, say below 2000 kg, use rubber isolators provided with the equipment. (b) If at the first harmonic frequency the structure vibrates as a whole block i.e. there is no relative movement between the adjacent layers of the component, avoid this resonance frequency and go for the next resonance frequency for stress relieving. (c) Run the vibrator at all the selected resonant frequencies for about 15 to 20 minutes using the Timer provided on the monitoring screen.
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Precautions: The following precautions should be observed during the VSR process: 1. Use the proper Exciter for the VSR treatment based on the weight of the job. 2. The accelerometer and the cable should be handled very gently as these are very sensitive and costly elements and the damages are not repairable. 3. If any unusual noise is heard during the VSR process, stop the process immediately by pressing the EMERGENCY switch provided on the front panel. Observe the work piece for any damage or crack. Or the vibrator may have got loosened. 4. If during the process, the amplitude decreases, then reduce the frequency and try to achieve the resonance. If still resonance is not obtained, increase the frequency and try to locate the resonance. This means that the resonance frequency might have sifted slightly towards lower side or slightly towards upper side. However if the resonance has sifted towards the lower side, it is clear indication of stress reduction. 5. During process the fault condition arises due to low voltage, over voltage, over current, short circuit or any internal panel fault, the process Exciter will stop. Immediately switch off the mains, after 5 minutes start the process again. If still the trip conditions prevail, consult factory.
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Supporting the component and Fixing the vibrator: When light powdery material is sprinkled on the job during vibration, they form the so-called nodal lines, under resonance condition. The nodal pattern indicates the dynamic shape of the job. If these lines are parallel to each other, then the job is said to be in the bending mode. If they are 90 degrees to each other then the job is said to be in torsion mode. At nodal lines the vibration force is negligible, i.e. the sinusoidal force passes through the neutral point. The position or type of support isolator is critical only in case of light and precision parts. Good quality isolators of suitable type are selected first. The job or component, which is to be stress relieved, should be supported so that the job is in balanced state. The support isolators should be placed in such a way that there is minimum static deflection while ensuring maximum dynamic deflection. If possible move the support isolators below the nodal line keeping in mind that the job is in balanced condition. The Vibration Exciter should be mounted conveniently on the job, preferably parallel to but away from the nodal lines. It should be rigidly clamped with the job. The vibrator can be mounted in any plane but preferably in the horizontal plane. The job should be vibrated with different position of vibrator, preferably at 90 degrees to the original position.
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Accelerometer functioning and handling: The Accelerometer is a device, which senses the vibration acceleration, converts this signal into electrical signal, and feeds this signal to the vibration meter. An accelerometer with its cable is the most costliest and delicate part of the entire VSR system and hence it should be handled very gently during the operation. The accelerometer should be mounted rigidly on the job, away from the nodal line, preferably corner of the structure is ideal. The peak reading of this signal on vibration meter indicates the resonance. During operation, prevent all loose parts from moving, otherwise some wrong readings will be indicated with regards to the resonance which may be misleading. Once again we remind you to avoid mishandling of accelerometer and cable, as these are very costly items and the damages caused are not repairable. Use of the Chart Recorder: With wider implication of the quality standard like ISO 9000, proof of treatment, method of deployment, and component identification are increasingly in demand. For this to accomplish, a stylish representation of the graph can be produced with the help of a chart recorder. It forms a reliable QA tool and contains useful design data. Requirements will very from company to company. Although the use of chart recorder is envisaged here, the process can still be employed without it. Once the operator has become fully conversant with the treatment method, the recorder may not be required. However, a chart recorder may be regarded as an essential tool for QA system or ISO 9000 standard. The chart recorder gets the signal from the vibration meter corresponding to the accelerometer signal. This signal is traced on the hard copy chart paper with respect to the time. Read the chart recorder instruction manual thoroughly, provided separately, before using it.
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How the stress level is evaluated & weather we can know that the
stresses have been relieved? Unfortunately there is no non-destructive technique available to indicate the Stress level. However, X ray defraction is the latest technique by which the effectiveness of the VSR is evaluated at CMTI, but again it is the destructive and the laboratory method. In Heat Treatment also no test is applied for the efficacy, and the procedure is blindly applied.
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VSR EQUIPMENT
Wait for few seconds to go to next screen
SCREEN 2
Note: If during the process Emergency switch is put on, the process will terminate at any stage. Sahyog Enterprise, Bombay 400 069. 15
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SCREEN 3
##
min
123.45 HZ 123.45 HZ
1234 micron
123.4 amps
TIME LAPSED
12 min
MANUAL INDEX
START
SET TOTAL RUN TIME: Sets the VSR operation time for the selected frequency TIMER MODE SELECT : Selects the mode of operation Timer/ Manual START : Starts the VSR process at selected frequency INDEX : Goes to manual index screen. SENSOR OPEN : sensor open will appear on the screen if the sensor is not connected or the sensor has failed. The process will stop EMS : EMS will appear when Emergency switch is pressed during the operation and the process will stop.
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INTERNAL INSPECTION REPORT 1. 2. 3. 4. 5. 6. 7. Description: Stress Relieving Equipment ( Vibratory Type) Specifications: As per PO- MATEC-SET/PO-001-10 Consignee: Machine Automation Joint Stock Company. Size of Lot: 1 Set Offered for inspection: 1 Set Date of inspection: 24/04/2010 Place of inspection: Sahyog Enterprise, 5, Tarun Industrial Estate, Mogra village road, Andheri East, Mumbai 400069 : Model VSR AT
Main Equipment
A. VSR Equipment Make : SAHYOG ENTERPRISE B. Exciter VSRE 05 & VSRE 20 make: Good Earth Engineering Industries C. Sensor with cable : ACD make, accelerometer sensor D. Clamps : 2 nos Big Clamps and 2 nos small Clamps E. Rubber isolators : 12 nos assorted 8. Specifications: Main Equipment: Value Specified Value Observed 230V, 1ph, 50Hz 230V, 1ph, 50Hz 0.37Kw, 3ph, 220V, 0 to 100 0.37Kw, 3ph, 220V, 0 to 100 Hz variable model VSRE 05 Hz variable model VSRE 05 0.75Kw, 3ph, 220V, 0 to 100 Hz variable model VSRE 20 0.75Kw, 3ph, 220V, 0 to 100 Hz variable model VSRE 20 0 to 100 Hz variable using potentiometer Electromechanical type pen type chart recorder, 100 mm width with 3 speeds
Exciter Rating
Frequency
0 to 100 Hz variable using potentiometer Vibration Exciter Electromechanical type Type of recorder pen type chart recorder, 100 mm width with 3 speeds
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Control Indications Value Specified 0 to 100 Hz 0 to 6000microns 100 mm Programmable Value Observed 0 to 100 Hz 0 to 6000 microns 100 mm Programmable through touch screen
Specified : Piezoelectric voltage output type, vibration sensor, with low impedance cable with magnetic base. Observed : Piezoelectric voltage output type, vibration sensor, with low impedance cable with magnetic base. Accessories C Clamps small C Clamps Big Set of Rubber for isolation Electric Input & Output cable 9. Test/ Inspection: Sr. No. Perameter 1 Vibrator Type Specified Electro mechanical Pen type 100mm 230V, 1 Phase,50Hz 0 to 100 Hz Piezo electric, voltage output type with low impedance cable and magnetic base Oberservation Remark Electro mechanical OK Value Specified 2 nos. 2 nos. 12 nos 1no. Each Value Observed 2 nos. 2 nos. 12 nos. 1no. Each
3 4 5 6 7
OK OK OK OK
Piezo electric, OK voltage output type with low impedance cable and magnetic base
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8 Accessories Clamps- Small 2Nos., ClampsBig 2 Nos., Set of rubbers- 12 Nos., Input-output cable- 1 No each, Chart pen 5 nos, Chart Paper 5 nos Clamps- Small 2Nos., ClampsBig 2 Nos., Set of rubbers- 12 Nos., Input-output cable1 No each, Chart pen 5 nos, Chart Paper 5 nos OK
10. Performance Report: The equipment was tested on the small job with VSRE 05 exciter along with sensor and cable. The parameters are as follows: VSRE 05 Exciter 22 Hz 600 microns 20
11. Conclusion: Specification, performance confirms specification as mentioned in PO.. Hence equipment found acceptable. SAHYOG ENTERPRISE
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