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REPRINT:
VIBRATORY STRESS RELIEF:
A FUNDAMENTAL STUDY OF ITS
EFFECTIVENESS
R. Dawson
D. G. Moffat
PH: 800.332.9770
FX: 888.964.3866
Reprinted from April, 1980, Vol. 102, Journal of Engineering Materials and Technology
R. Dawson
Group Purchase Department
Perkins Engines Limited,
Peterborough
D. G. Moffat
Department of Mechanical Engineering,
University of Liverpool,
Liverpool, England
Introduction
Vibratory stress relief (V.S.R.), as an alternative to natural
ageing or thermal stress relief for reducing residual stresses in
structures, has been debated for some 35 years. Investigations
have ranged from tests on simple fatigue type specimens
[1-3], with residual stresses induced by shot-peening or plastic
bending, to vibration tests on castings and weldments [4-11].
Commercial processes normally involve clamping an eccentric-mass electric motor to the work-piece and vibrating at
various resonant frequencies for periods of the order of 15
minutes. Manufacturers claim to achieve greatly increased
dimensional stability during machining and subsequent
operation of castings and weldments, up to many tons in
weight, as a result of applying the V.S.R. process. The
evidence that the process does indeed produce increased
dimensional stability is impossible to deny. However, the
various research investigations, aimed at assessing and explaining the process, have arrived at a variety of conclusions
ranging from open skepticism to guarded optimism.
Early work by McGoldrick and Saunders [4] on castings
and welded space frames, although giving no useful quantitative data, concluded that vibrational stress relief depended
upon the occurrence of plasticity at some time during the
treatment, and that to achieve the necessary amplitudes,
resonant vibration should be used. These conclusions were
supported by the findings of Moore [1] using shot-peened
tapered cantilever beams.
In the early 1960's, Buhler and Pfalzgraf contributed four
papers [6 and 12-14] on the subject, describing tests on a
variety of castings and weldments. Their conclusions were not
encouraging, although they did achieve a 20 percent reduction
in residual stress when they increased the applied cyclic stress
to around the fatigue limit of the steel used. They were clearly
restricted by their concern about potential fatigue failures,
and hence never attained the stress amplitudes that would be
required for significant stress relief. Adoyan, et al. [7 and 8]
Table 1
Material
Hot-rolled mild steel
Cold-drawn mile steel
Aluminium alloy
Material properties
Ultimate tensile
Strength
lbf/in2 (MN/m2)
57,000 (393)
88,500 (610)
40,200 (277)
Si Mn
0.13 0.62
S
P
0.058 0.032
Ni Cr
0.055 0.04
Mo
Cu
0.01 0.05 %
was the same for both the steel and aluminum beams.
[Resonance depends on the ratio (E/) which is approximately
constant for most engineering metals.]
Using the test arrangement shown in Fig. 1, it was possible
to test a residually stressed specimen simultaneously with a
non-residually stressed specimen at exactly the same vibrating
conditions. Strain gauges 1 and 2, and the control gauge 3, all
underwent high cyclic strain amplitudes, being near the root
of the cantilever, while gauge 4 experienced lower values.
Each run therefore gave results for two cyclic strain amplitudes. The control gauge 3 was important as a check on any
gauge drift that might occur during cycling. In the event, drift
was negligible and thus any changes in the output from gauges
1, 2, and 4 were associated with residual stress changes during
cycling.
Use was also made in the vibration set-up of the fact that
the resonant frequency could be raised by shortening the
cantilever, or lowered by adding weights to the cantilever tips.
Using this adjustment, tests were conducted at 33 Hz and 92 Hz
in addition to the main bulk of the tests at 63 Hz.
The electronics associated with the shaker excitation and
strain gauge output were arranged to provide a "closed loop"
system of control. The form of the strain gauge output during
vibration consisted of a constant cyclic strain amplitude and a
variable mean strain, the latter being due to stress
redistribution. By using a purpose-build filter system, the
output from gauge 1 was split into its a-c and d-c components
(shown simply in Fig. 3) such that a continuous recording of
both could be obtained on an ultraviolet chart recorder.
Strain gauge readings from each of the four strain gauge
were also noted before and after the vibration process using
the static strain gauge bridge, which had a better resolution
than the U.V. recorder.
Vibration Tests
5 Enks,
F., "Artificial Ageing of Casting. With Enke Vibrator.," Machinery, Vol. 94,
Cast Iron and Steel by Mechanical Vibration and Continued Holding in the Atmosphere,"
V.~1. Verlag, 1962, 56 pp. (translated by B.C.I.R.A: Report 20a, 1964. Reviewed by P.
Sieben, Giesserei, Vol.51, 1964).
7 Adoyan, G. A., Gerchikov, A. M., and Gini, E. Ch., "The Effectiveness of the Vibration
Ageing of Iron Castings," Russian Castings Production. 1964, pp. 83-85.
8 Adoyan, G. A. et al., "The Vibratory Stress Relieving of Castings,'' Machines and
Tooling. Vol. 38, No.8, 1967, pp. I 8-22.
9 Lokshin, I. Kh., "Vibration Treatment and Dimensional Stabilisation of Castings,"
Russian Castings Production, 1965, pp. 454-456.
10 Wozney, G. P., and Crawmer, G. R., "An Investigation of Vibrational Stress Relief in
Steel," Welding Res. Sup., Vol. 23, No.9, 968, pp.411.419.
11 Cheever, D. L., "Vibrational Conditioning of Metallic Structures,'' 1972, private report
on a 16 month investigation carried out by Battelle Memorial Institute.
12 Buhler II., and Pfalzgraf, H. C., "Investigations Into the Reduction of Residual Welding
Stresses by Alternating Stress Tests or Mechanical Vibration," Inst, of Machine Tools and
Shaping Technology of the University, Hanover. Schweisse and Schreiden, Vol. 16, 1964. No.
5. (also designated Internat. Inst. of Welding Documents HS/HWDOC X-336-64).
Acknowledgment
The support of the Science Research Council in providing a
Research Studentship for Dr. Dawson
is gratefully
acknowledged.
References
13 Buhler, H., and Pfalzgraf. I-I. C., "Discussion on the Reduction of Residual Stresses in
Workpieces Made of Cast Iron," Werkstalt und Betrieb, No.2,1964,171, pp. 36-43.
14 Buhler, H.,and Pfalzgraf, H. C., "Relief of Casting Stresses by Jotting: Part 1, "Foundry
Trade Journal, 1965, Vol.118, pp. 567-569.
15 Sagalevich, V. M., and Meister, A. M., "Eliminating Welding Strains and Stresses in
Sheet Construction by Vibration Under Load," Svar Proit 1971. No. 9, pp. 1-4.
1 Moore, U. F., "A Study of Residual Stresses and Size Effect and a Study of the Effect of
Repeated Stresses on Residual Stresses Due to Shot Peening of Two Steels," Proc. Soc. Exp.
Stress Anal, vol.2, Not, 1944, pp. 170-177.
2 Pattinson, E J., and Dugdale, D. S., "Fading of Residual Stresses Due to Repeated
Loading," Metallurgia, Nov. 1962, pp.228-230.
3 Kodama, S., "On the Decrease of Residual Stress Due to Cyclic Stress," Faculty of
Technology, Tokyo Metropolitan University, V-44l/R, 1972/1973.
4 McGoldrick, R. T., and Saunders, I-I. E., "Some Experiments in Stress Relieving
Castings and Welded Structures by vibration," J.A.S.N.E., Vol. 55, 1943, No. 4, pp. 589-609.
47-St.
18 Dreger, D. R., "Good Vibes Reduce Stresses in Metal Parts," Machine Design, Vol.50.
No.13,1978, pp. 100-103.
19 Rosenthal, D. and Norton, J. T., "A Method of Measuring Triaxial Residual Stresses in
Plates," J. A. Weld. Soc., Welding Supplement. Vol. 24, pp. 295.307, 1945.
20 Leaf, W., "Techniques in Residual Stress Analysis." Exp. Stress Anal., Vol.9, No.2,
pp.133-139.
21 Dawson, K., "Residual Stress Relief by Vibration," Ph.D. thesis, Liverpool, Dec. 1975,
22 Manson, S. S., Thermal Stress end Low Cycle Fatigue. McGraw-Hill, 1966.