Manufacturing processes inevitably induce a state of residual stress into materials and products. These residual stresses pose a large potential problem, in terms of dimensional stability and reduced fatigue life. Ideally, residual stresses should be reducible to low levels. There are three methods in general usage for the relaxation of these stresses, - Annealing, Shakedown and Vibratory Stress Relief (VSR). A previous study had suggested that vibration during and/or after welding may usefully modify residual stresses due to welding. This has been termed Vibratory Weld Conditioning (VWC). A comparative study of the methods is presented in section 1.4. The use of VSR, though widespread, has been adopted on a case-by-case basis, due to the lack of understanding of the processes at work. The purpose of this work was to investigate and validate the VSR/VWC method as a proposed alternative to the processes mentioned above. In order to do this a series of tests were devised in which the specimens were welded as a mechanism of stress induction. The residual stresses were measured before and after welding and vibration by means of a scanning X-ray diffractometer. In Chapter 1, the study of Residual Stress (source, formation etc), Welding Metallurgy and a comparison of VSR/VWC with other treatment methods are presented. In Chapter 2, a detailed review of literature is presented, where the accessible literature on VSR/VWC to date are included. In Chapter 3, the theoretical background of Modal Analysis, the Measurement of Dynamic Induced Stress and Measurement of Residual Stressesis discussed. In Chapter 4, the FE analysis of different structures is presented. In the FE analysis, different properties of the structures were determined using the FE model to aid the VSR/VWC study. The experimental investigations are presented in Chapter 5, which is divided into the following parts: Modal Analysis (experimental), Calibration of the X-ray measurements, VSR/VWC treatments, Cryogenic treatment, Fatigue Test and Metallurgical Investigation of VSR/VWC treated specimens. At the outset of the experimental work, the calibration of the X-ray diffractometer was carried out. After calibration of the X-ray and the X-ray Elastic Constant the error band of the diffractometer was significantly reduced. The practical modal analysis of the "8" frame was carried out to determine the modal characteristics of the frame to aid the VSR investigation of the frame. The VSR/VWC treatments are divided into "during welding" and "post weld" treatments and are presented in 10 different experiments. First, the "during welding" treatments were carried out. Investigation was started with application of tensile and compressive static stress to the specimens during welding and cooling. It was observed that the tensile induced stress decreased, and compressive induced stress increased the residual stresses. Rigid body motion (RBM) vibration showed no effect on the residual stresses. The cantilever beam test of the flexural vibration test showed some important characteristics, where the longitudinal residual stresses were found to decrease with application of small-induced stress. An increase in applied stress or time of vibration did not cause any more reduction. The transverse residual stresses increased with application of small-induced stresses. With increase in the applied stress the residual stresses decreased. High frequency vibration in both RBM and flexural vibration was found to be ineffective in reducing the residual stresses. The flexural vibration of the Four-Roller Supported beam showed a very confusing result, where no particular trend of the residual stresses was found. The combined mode of vibration (longitudinal and flexural) treatment showed no effect on residual stresses. The "post weld" treatment of the specimens showed a significant reduction in the residual stresses, where the reduction in the residual stresses were found to be a function of applied stress, while the vibration time effect was found to be negligible. A complex shape of reduction in the residual stresses were found along the width of the specimens, which made it impossible to develop any plastic flow model for the reduction in the residual stresses. Torsional test revealed a very important property of the residual stresses, where the residual stresses were found to decrease by a significant amount with application of very small induced stress. High induced stress only redistributed the residual stresses. Cryogenic treatment caused no reduction in the residual stresses. Contrarily the same specimen showed a significant reduction after VSR treatment. The fatigue test showed an increased fatigue life of the VSR treated specimens, while the thermally treated specimens showed a decreased fatigue life. The vibrated specimens showed highly oriented ferrite crystals in directions with Miller [111] to the stress axis. The hardness of the VSR treated specimens was found to increase significantly in comparison to the unvibrated specimens.

Made available in DSpace on 2014-06-11T19:27:11Z (GMT). No. of bitstreams: 0 Previous issue date: 2011-08-12Bitstream added on 2014-06-13T19:34:58Z : No. of bitstreams: 1 santos_ch_me_guara.pdf: 2207083 bytes, checksum: 6c810376924fcd84cb5a78acf9dd1896 (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / A estampagem de chapas metálicas é importante e se destaca entre os processos de conformação, pois, é possível de se obter vários produtos com alta produtividade e baixo custo. No entanto, como todo processo de conformação pode haver alguns inconvenientes, como as tensões residuais, que são geradas devido ao aumento da resistência mecânica do material resultante da deformação plástica a frio ou devido à geometria complexa da peça, com regiões de tração e compressão. Algumas medidas são realizadas dentro da área fabril para minimizar o problema e assim as peças irem para a etapa seguinte de conformação. Uma delas é a realização de tratamento térmico de alívio das tensões residuais de forma manual. O problema é que esse processo não garante nenhum controle da microestrutura e também não há garantia que as tensões foram aliviadas e como consequência peças são sucateadas na etapa seguinte de conformação, acarretando um aumento maior dos custos de fabricação. Neste trabalho foi realizado um estudo do alívio das tensões residuais através de vibrações mecânicas abaixo da frequência de ressonância em uma peça estampada a frio. O objetivo deste trabalho é avaliar os efeitos das vibrações mecânicas abaixo da frequência de ressonância no alívio das tensões residuais, de tal forma que possa ser uma opção ao tratamento térmico. Os resultados mostram que ouve redução nas tensões residuais, porém novos estudos devem ser realizados para garantir a eficácia deste processo / The stamping of sheet metal is important and stands out among the forming processes, therefore it is possible to obtain various products with high productivity and low cost, however, the whole process of conformation can bring some drawbacks, such as residual stresses, that are generated due the rigidity of the material against cold plastic deformation or due the geometry complex of the piece, with areas on tension and compression. Some processes are carried out within the factory area to minimize the problem and so the pieces go to the next step of forming, for instance perform heat treatment relief residual stresses. The problem is that this process does not guarantee any control of the microstructure and also there is not guarantee that the tensions were reduced and failure pieces in the next step of conformation, resulting in a greater increase in manufacturing costs. In this paper has been studied relief residual stress by mechanical vibrations, with carry out of treatment relief from vibrations below the resonant frequency in component cold drawned. The objective of this study is to evaluate the effects of mechanical vibration below the resonant frequency to relieve residual stresses, so that might be an option to heat treatment. The results show a reduction in residual stress; however, we have to compare them with other treatments for which they can ensure the effectiveness of mechanical vibrations

Orientador: Ângelo Caporalli Filho / Banca: Valdir Alves Guimarães / Banca: Wyser José Yamakami / Resumo: A estampagem de chapas metálicas é importante e se destaca entre os processos de conformação, pois, é possível de se obter vários produtos com alta produtividade e baixo custo. No entanto, como todo processo de conformação pode haver alguns inconvenientes, como as tensões residuais, que são geradas devido ao aumento da resistência mecânica do material resultante da deformação plástica a frio ou devido à geometria complexa da peça, com regiões de tração e compressão. Algumas medidas são realizadas dentro da área fabril para minimizar o problema e assim as peças irem para a etapa seguinte de conformação. Uma delas é a realização de tratamento térmico de alívio das tensões residuais de forma manual. O problema é que esse processo não garante nenhum controle da microestrutura e também não há garantia que as tensões foram aliviadas e como consequência peças são sucateadas na etapa seguinte de conformação, acarretando um aumento maior dos custos de fabricação. Neste trabalho foi realizado um estudo do alívio das tensões residuais através de vibrações mecânicas abaixo da frequência de ressonância em uma peça estampada a frio. O objetivo deste trabalho é avaliar os efeitos das vibrações mecânicas abaixo da frequência de ressonância no alívio das tensões residuais, de tal forma que possa ser uma opção ao tratamento térmico. Os resultados mostram que ouve redução nas tensões residuais, porém novos estudos devem ser realizados para garantir a eficácia deste processo / Abstract: The stamping of sheet metal is important and stands out among the forming processes, therefore it is possible to obtain various products with high productivity and low cost, however, the whole process of conformation can bring some drawbacks, such as residual stresses, that are generated due the rigidity of the material against cold plastic deformation or due the geometry complex of the piece, with areas on tension and compression. Some processes are carried out within the factory area to minimize the problem and so the pieces go to the next step of forming, for instance perform heat treatment relief residual stresses. The problem is that this process does not guarantee any control of the microstructure and also there is not guarantee that the tensions were reduced and failure pieces in the next step of conformation, resulting in a greater increase in manufacturing costs. In this paper has been studied relief residual stress by mechanical vibrations, with carry out of treatment relief from vibrations below the resonant frequency in component cold drawned. The objective of this study is to evaluate the effects of mechanical vibration below the resonant frequency to relieve residual stresses, so that might be an option to heat treatment. The results show a reduction in residual stress; however, we have to compare them with other treatments for which they can ensure the effectiveness of mechanical vibrations / Mestre

Submitted by AMÉRICO BIANCALANA NETO null (abiancalana@confab.com.br) on 2016-09-21T15:55:15Z No. of bitstreams: 1 DISSERTAÇÃO_Américo Biancalana Neto.pdf: 6507235 bytes, checksum: 42c17d17ef5a510dd34876071a8ff043 (MD5) / Approved for entry into archive by Juliano Benedito Ferreira (julianoferreira@reitoria.unesp.br) on 2016-09-26T19:52:21Z (GMT) No. of bitstreams: 1 biancalananeto_a_me_guara.pdf: 6507235 bytes, checksum: 42c17d17ef5a510dd34876071a8ff043 (MD5) / Made available in DSpace on 2016-09-26T19:52:21Z (GMT). No. of bitstreams: 1 biancalananeto_a_me_guara.pdf: 6507235 bytes, checksum: 42c17d17ef5a510dd34876071a8ff043 (MD5) Previous issue date: 2016-07-22 / Os processos tradicionais de produção de tubos API 5CT N80Q envolvem processos de bobinamento e desbobinamento, conformação por dobramento, soldagem, etapas de usinagem e expansão dos diâmetros interno e externo, tratamentos térmicos de têmpera e revenimento e endireitamento. Essas etapas são responsáveis por introduzir tensões residuais no material constituinte do tubo. Estas tensões residuais podem alcançar valores próximos aos do limite de escoamento do material base do tubo, podendo produzir distorções geométricas, falhas prematuras, baixa resistência à corrosão, e diminuição na sua capacidade de absorção de cargas em trabalho. O método mais utilizado para alívio de tensões é o tratamento térmico. Porém, a aplicação de vibrações mecânicas, (Vibratory Stress Rielif) para reduzir e redistribuir as tensões residuais em estruturas conformadas a frio e em estruturas soldadas, tem sido utilizada com sucesso em várias partes do mundo, principalmente nos Estados Unidos, China e Canada. Para verificar a viabilidade deste processo, como um método alternativo para o alivio de tensões, selecionamos um tubo API 5CT 80NQ, com diâmetro de 178 mm com 8,05 mm de espessura e 3000 mm de comprimento. Os ensaios de vibração foram executados na frequência de ressonância do tubo, através de um indutor de vibração montado no seu comprimento médio, dentro de um intervalo de tempo correspondente ao seu peso. Comparando os valores de tensões residuais existentes no tubo antes e após o tratamento de vibração conseguimos uma redução média de 16% no valor das mesmas. Para a caracterização mecânica do tubo, antes e depois do processo vibratório, foram realizados os seguintes ensaios conforme a norma API 5CT 2001: impacto Charpy “V”, ensaios de tração e dureza Rockwell C, tanto no metal base do tubo, como na região da solda. Foi realizada, também, a sua caracterização micro estrutural através, microscopia ótica, antes e depois dos ensaios de vibração. Para avaliação das tensões residuais, antes e após os ensaios de vibração, foi utilizado o método de secção longitudinal de um anel (splitting ring test) conforme a norma ASTM EN 1928-13. / The traditional production processes API 5CT N80Q pipes involve coiling and uncoiling processes the plate, conformation by bending, welding, machining steps and expansion of its internal and external diameters, heat treatment of quenching and tempering and straightening. These steps are responsible for introducing residual stresses in the material of the tube. These residual stresses can reach values close to the yield strength of the pipe`s base material and may produce geometric distortions, premature failure, low corrosion resistance and reduction its capacity of absorption loads in the work. The most widely used method for relieving stress is the heat treatment. The application of mechanical vibrations, Vibratory stress relief ( VSR), to reduce and redistribute the residual stresses in cold shaped structures and welded structures, has been used with success in various parts of the world, especially the United States, China and Canada. Thus, the mechanical vibration, Vibratory stress relief (VSR), can prove to be an interesting process to relieve stress in the tubes. To verify the feasibility of this process, as an alternative method for the relief of stresses, we selected an API 5CT 80NQ tube with a diameter of 178 mm, with 8.05 mm thickness and 3000 mm in length. Vibration tests were performed in pipe resonance frequency, via a vibration-inducing mounted at its mid-length, within a time corresponding to their weight. Comparing the values of residual stress existing in the tube before and after the vibration treatment achieved a mean reduction of 16 % in the amount thereof. For the mechanical characterization of the pipe, before and after the vibration process, the following tests were conducted according to API standard 5CT 2001: Charpy 'V', tensile tests and hardness Rockwell C, both in the metal base tube, and in the weld region. It was also carried out their microstructural characterization through optical microscopy before and after the vibration tests. To evaluate the residual stress before and after the vibration tests, we used the ring splitting test according to ASTM E1928-13.