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2008
A finite element model is developed for the simulation of vibration stress relief (VSR)
after welding. For the nonresonant vibration, the reduction in stress strongly depends
on the amplitude of vibration. For the resonant vibration, the vibration frequency
is the key for stress relief. The vibration frequency should be close to the structure
natural frequency for the desired vibration mode. Only small vibration amplitude is
required, which will be amplified during vibration. Vibration time does not have a
major impact on vibration stress relief. When the amplitude of vibration stress relief
is large, the treatment will be more effective.
KEY WORDS Residual stress; Vibration stress relief; Simulation
1. Introduction
Welding process inevitably induce residual stress into welded structures. This creates
potential problems in terms of dimension stability. Traditionally, post-weld heat treatment
(PWHT) was used to relieve residual stress, which is an effective process, but it suffers from
numerous disadvantages: oxidization of heating surface and change in material properties.
Vibratory stress relief has been proposed as an alternative to relieve weld residual stress
for several years.
Recently, various industries have used the vibratory stress relieving methods to reduce
the residual stress in welded components. As the mechanism of vibration stress relief is not
well understood, this process is not widely used in industries. If the vibration applied on a
welded structure is not adequate, the weld residual stress cannot be reduced. Furthermore,
as the cost of weld residual stress measurement is high and time consuming, it is difficult
to know the extent of reduction of residual stress by the VSR. With the development of
modeling technology, it is possible to model the process of VSR using a commercial finite
element code Marc.
In this article, a finite element model has been developed to investigate the mechanism
of the VSR process and the effect of the parameters of VSR, vibration time, frequency and
amplitude, on the reduction of weld residual stress. A three-dimensional solid modal was
∗
Corresponding author. Tel.: +86 10 82317756.
E-mail address: skyzh@me.buaa.edu.cn (X.C. Zhao)
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3. Thermal Analysis
The temperature histories predicted in the thermal analysis were inputted to a thermal-
mechanical model to perform weld stress analyses. Proper boundary conditions were added
to simulate the clamp of the fixed end. Fig.4 shows the distribution of transverse and
· 291 ·
6. Resonant Vibration Stress Relief Fig.7 Mode shape of first natural frequency.
Fig.8 Effect of frequency on displacement: (a) f =25 Hz; (b) f =70 Hz; (c) f =78.975 Hz.
Another interesting phenomenon can be observed in Fig.8. For the cases with frequency
70 Hz and 78.975 Hz, the displacement amplitude was amplified and then periodically
reduced. The cycle time was different between these two cases. These phenomena could
be induced by structure damping.
The displacement is amplified to 19.99 mm for the case with 20 N force and 41.26 mm for
the case with 100 N force. It is relevant that the amplified displacement amplitude is no
longer decreased for the case with 100 N force. This could be attributed to the fact that
magnitude overcomes the effect of the structure damping. The amplified ration for the
case with 20 N is approximately equal to two, but for the case with 100 N, it is smaller
than 10.
7. Conclusion
A VSR finite element model has been developed, which can be used to better understand
the mechanism of VSR and optimize the parameter of VSR process. The major conclusions
from the studies of nonresonant VSR and resonant VSR are as follows:
(1) Load amplitude is the key parameter that reduces weld residual stress. For nonres-
onant VSR, load amplitude should be proper, otherwise residual stress cannot be reduced
or new residual stress will be produced further. For resonant VSR, a small load is required,
which will be amplified large enough to reduce residual stress.
(2) Vibration time does not have a major impact on VSR. Most stress relief happened
in early load cycles. If vibration time is increased, fatigue life can be decreased.
(3) To reduce weld residual stress, a proper vibration mode shape should be selected.
Acknowledgements—This work was supported by the National Defence Basic Research and Development
Programme of China (No. 59975008).
REFERENCES
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[2] A.S.M.Y. Munsi, A.J. Waddell and C.A. Walker, Mater. Sci. Technol. 17 (2001) 601.
[3] A.S.M.Y. Munsi, A.J. Waddell and C.A. Walker, J. Strain Anal. 36(5) (2001) 453.
[4] W.F. Hahn, PhD Dissertation (Alfred University, Alfred, 2002).
[5] Meta-Lax, http://www.meta-lax.com/Home/Literature/literature.html
[6] J. Goldak, A. Chakravarti and M. Bibby, Metall. Trans. 15B(2) (1984) 299.