Laiwu vibration aging machine, automatic stress relief machine

Jiugong Instrument - Domestic Vibration Aging Equipment - Stress Reliever‍Manufacturers of equipment and time processing machines!

Overview of vibration aging machine products:

Vibration aging is the use of resonance principle to eliminate and homogenize residual stresses in metal castings, forgings, welded structural components, non-ferrous metals and other parts, in order to prevent dimensional deformation and cracking of the parts. Compared to traditional heat aging methods, it can save energy95%Save production costs80~90%Shorten production cycle90%Left and right, without producing aging oxidation skin, etc; No environmental pollution, not limited by part size, site, etc., and the time effect is intuitive and superior to thermal aging.

Vibration aging machine is a new type of aging equipment that eliminates residual stress in workpieces through vibration. Its core function is to solve deformation and cracking problems caused by residual stress in mechanical manufacturing. Its working principle is to use a vibration source (a motor with an eccentric block) to generate periodic excitation force, causing the workpiece to enter a resonant or sub resonant state, activating internal grain slip and dislocation motion, releasing residual stress, and optimizing stress distribution.

Compared to traditional thermal aging (high temperature energy consumption, easy to change material properties) and natural aging (long cycle, low efficiency), vibration aging machines have significant advantages: no need for high temperature, energy-saving and environmentally friendly; Short lead time (completed within a few hours) and high efficiency; Without changing the metallographic structure and mechanical properties of the workpiece, it is suitable for large, complex, or unheated workpieces (such as machine tool beds, pressure vessels, aerospace components).

The equipment mainly consists of a vibration source, a control unit (sensors, controllers, monitoring and adjusting vibration parameters), and a support system (rubber pads, etc., to reduce the impact on the foundation). With the development of technology, intelligent models have passedAIAlgorithm optimization of vibration parameters to further improve efficiency and stability.

Its applications cover fields such as mechanical manufacturing, aerospace, chemical engineering, power, steel structures, etc. It is an important equipment for eliminating residual stress in modern manufacturing industry.

Vibration aging machine is a specialized equipment based on the principle of mechanical vibration, used to eliminate or reduce residual stress in metal components. It is widely used in mechanical manufacturing, aerospace, automotive, power and other fields, and is an energy-saving and environmentally friendly technological means to replace traditional thermal aging.

1、 Working principle

The core of vibration aging is resonance effect: periodic mechanical vibration is applied to the component through a vibration source (such as an eccentric motor). When the vibration frequency is consistent with the natural frequency of the component, the component enters a resonance state and produces amplitude vibration. At this point, residual stresses inside the component are superimposed with vibration stresses. When the composite stress exceeds the yield limit of the material, plastic deformation occurs locally in the component, releasing residual stresses and making the stress distribution more uniform.

To avoid damage to components caused by resonance, modern vibration aging machines often use sub resonance technology (i.e. vibration frequency close to but slightly lower than the natural frequency), which improves equipment safety and applicability while ensuring stress relief effect.

2、 Core components and system composition

The vibration aging machine mainly consists of four parts:

1. Vibration source: Usually a motor with an eccentric block, the amplitude (vibration intensity) is changed by adjusting the angle of the eccentric block, and the vibration frequency is changed by adjusting the motor speed.

2. Sensors: including acceleration sensors (collecting component vibration signals) and strain sensors (monitoring stress changes), used to provide feedback on the vibration status and stress relief effect of the component.

3. Control system: The core is the signal processing unit, which adjusts the frequency and amplitude of the vibration source in real time by collecting sensor data, ensuring that the components are in a vibration state (resonance or sub resonance). Some devices are integratedAIAlgorithms can automatically identify the natural frequency of components and optimize parameters.

4. Fixtures and supports: used to fix components and ensure effective transmission of vibration energy. The support point should avoid the stress concentration area of the component to avoid affecting the vibration effect.

3、 Typical workflow

1. Component fixation: Place the component to be processed on a flexible support (such as a rubber pad) and fix it with a fixture to ensure that the component does not shift during vibration.

2. Sensor installation: Install acceleration sensors and strain sensors at stress concentration areas of components (such as welds and casting defects), and connect them to the control system.

3. Sweep frequency analysis: Start the vibration source, gradually adjust the frequency from low to high, record the vibration response of the component (such as amplitude and phase), and find its natural frequency or sub resonant frequency.

4. Timeliness treatment: fix the vibration frequency at a certain value and maintain it for a certain period of time (usually1-3During the process, the control system monitors vibration parameters and stress changes in real-time to ensure process stability.

5. Effect detection: After the processing is completed, stress testing (such asXVerification of residual stress relief rate using X-ray diffraction and blind hole method (generally achievable)30%-70%In some cases, it can be achieved80%Above).

4、 Main application areas

Vibration aging machine is suitable for various metal components, especially in scenarios where thermal aging is not possible or inconvenient. Its main applications include:

• Mechanical manufacturing: machine tool bed, gearbox, castings, forgings, etc., eliminating casting/Forging residual stress to prevent deformation after processing.

• Aerospace: Aluminum alloy aircraft parts, titanium alloy engine components, etc., to avoid material performance degradation caused by thermal aging (such as grain growth and hardness reduction).

• Automotive industry: eliminating welding or stamping residual stresses and improving fatigue life in engine cylinder blocks, crankshafts, chassis components, etc.

• Electrical equipment: turbine blades, generator bases, etc., to eliminate residual stresses from heat treatment and prevent fracture during operation.

• Steel structures: bridges, building steel beams, pressure vessels, etc., eliminate residual stresses in welds and improve structural safety.

5、 Advantages compared to traditional thermal aging

1. Energy saving: Heating is required for thermal aging500-600℃It takes a few days, while vibration aging only requires electric drive, reducing energy consumption80%The above.

2. Environmental Protection: No exhaust gas or wastewater discharge, avoiding environmental pollution caused by thermal aging.

3. Efficient: Short processing time（1-3Hour by hour, it can achieve assembly line operation and improve production efficiency.

4. Wide applicability: It can handle large components (such as machine tool bed bodies weighing tens of tons) or complex shaped components (such as box type parts) without the need for large heating furnaces.

5. Not changing material properties: It will not cause grain growth, hardness decrease, or oxidation decarburization of the material, especially suitable for sensitive materials such as aluminum alloys and titanium alloys.

sixFuture Development Trends

1. Intelligence: CombiningAIUsing machine learning to automatically identify the natural frequency of components, dynamically optimize vibration parameters, and improve stress relief efficiency and consistency.

2. Portability: Develop small, handheld, or vehicle mounted vibration aging machines for on-site processing of large components such as bridges and wind turbines, reducing transportation costs.

3. Multifunctional: Integrating multiple aging methods such as vibration, ultrasound, and impact, targeting different components (such as surface stress)vsRealize precise processing of internal stress.

4. Dataization: By using IoT technology to store and analyze vibration data, establish a stress relief database to provide reference for subsequent component design.

   In short, as an efficient and energy-saving residual stress relief device, the vibration aging machine will further expand its application scope with the continuous advancement of technology and become an indispensable key equipment in the manufacturing process of metal components.