Patent Application
20220177988
This disclosure relates to a needle-peening method and, specifically, a needle-peening method of peening a weld toe of a welded joint for welding sheet metal.
Typically, in most of automotive suspension parts, steel parts made of steel sheets are joined with each other by a welded joint. A load is repeatedly applied to the suspension part when an automobile is driving so that fatigue may be caused in the suspension part. It is known that such fatigue tends to be caused at a weld, and most of the fatigue is a fracture mode caused by a crack parallel to a welding direction. The fracture mode is a fracture mode caused by a bending moment load in a direction parallel to the welding direction, that is, a stress perpendicular to the welding direction. Fatigue properties of the weld cannot be improved by high-strengthening of base metal, but is effectively compensated by increasing the thickness. Thus, the fatigue properties hinder reducing the wall thickness of the steel parts used for the suspension part. Accordingly, for the purpose of reducing the wall thickness, various techniques have been implemented to improve the fatigue properties of the weld.
Most of the fatigue is caused at a weld toe of the weld, and it is known that a main cause of the fatigue is stress concentration on the weld toe and a tensile residual stress caused by welding. To solve this problem, as a method of relieving stress concentration by deforming the shape of the weld toe, and giving a compressive residual stress by plastic deformation at the same time, there has been implemented needle-peening processing of peening the weld toe by a vibrating hammer tip or peening pin (Japanese Patent No. 3002229 and Japanese Patent Application Laid-open No. 2014-008507). However, in the methods disclosed in JP '229 and JP '507, a distal end radius of the hammer tip or a radius of curvature of a distal end of the peening pin is too large compared to a radius of curvature of the weld toe (weld extra-banking toe) so that there has been the problem that overlapping defects are caused at the weld toe due to a plastic flow of a material to be peened, fatigue is caused from the overlapping defects at the weld toe as a starting point, and the fatigue properties are not sufficiently improved.
Thus, Japanese Patent No. 4837428 discloses a needle-peening method of using a pin having a distal end radius equal to or larger than 1.0 mm and equal to or smaller than 2.0 mm to prevent overlapping defects from being caused when a plastic flow of metal is caused by impact of the pin. Japanese Patent Application Laid-open No. 2013-71140 discloses a needle-peening method of preventing overlapping defects at the weld toe based on a relation between a shape of a welding metal part and a distal end radius of a vibration pin. Additionally, there is disclosed a method of grinding the weld toe by using a grinder as preprocessing.
Furthermore, to further increase the compressive residual stress introduced by needle-peening, Japanese Patent Application Laid-open No. 2006-167724 discloses a method of performing peening processing by a plurality of fixed pins that are arranged at intervals to be parallel with each other and have a predetermined angle with respect to a welding direction so that bulging edges of peening marks formed by needle-peening overlap with each other.
Most of automotive suspension parts are obtained by joining steel sheets having a thickness equal to or larger than 0.8 mm and equal to or smaller than 3.5 mm as base metal by a welded joint, and a radius of curvature of a weld toe of such a welded joint for steel sheets is about 0.2 mm to 1.0 mm. Thus, if the method disclosed in JP '428 is applied to the welded joint for the steel sheets, even when peening is performed by using a peening pin having a distal end radius of 1.0 mm, there has been the high risk that an overlapping defect 47 is caused at the weld toe as illustrated in
In the method disclosed in JP '140, overlapping defects can be prevented from being caused based on a relational expression between the distal end radius of the peening pin (vibration pin) and a weld toe shape, but a flank angle of the welded joint is required to be equal to or smaller than 15 degrees, the welded joint in which the radius of curvature of the weld toe is 0.3 mm, for example. However, considering that a typical value of the flank angle is about 60 degrees, there has been the problem that the method disclosed in JP '140 cannot be applied to most welded joints made of steel sheets as base metal.
A driving force required to provide pressure for applying plastic deformation is increased as the distal end radius of the peening pin is increased so that, when using a peening pin having a distal end radius equal to or larger than 1.0 mm for a high-strength material, it has been required to use an expensive large device of an air-driving type (JP '507), an ultrasonic type (JP '428, JP '724) or the like. On the other hand, if the distal end radius of the peening pin is small, the overlapping defect 47 at the weld toe as illustrated in
When a load is applied in a direction orthogonal to the overlapping defect 49 at the peening mark end continuous to the welding direction, the overlapping defect 49 is assumed to be a notch continuous to a direction orthogonal to a direction of repeated tensile stress of fatigue. In such a notch, a stress caused at a bottom part of the notch becomes higher than that of a notch continuous to another direction (for example, a direction parallel to a tensile stress direction) so that generation and development of a crack are accelerated. Due to this, there has been the problem that, when the load applied in the direction orthogonal to the welding direction is loaded onto the weld toe, if the overlapping defect 49 at the peening mark end is formed in parallel to the welding direction, fatigue properties are prevented from being improved by peening with the peening pin.
Such a problem is also found in the method disclosed in JP '724 to perform peening processing with a plurality of pins so that bulging edges of peening marks overlap with each other, and there has been the problem that development of a crack cannot be prevented against a stress perpendicular to the welding direction.
It could therefore be helpful to provide a needle-peening method that can relieve stress concentration on the weld toe and can prevent overlapping defects from being caused.
We thus provide a needle-peening method of peening a weld toe of a welded joint for welding and joining two pieces of sheet metal by using a peening pin, wherein a radius of curvature of a cross section perpendicular to a welding direction at a distal end part of the peening pin is equal to or larger than 0.05 mm and smaller than 1.00 mm, and the method includes: vibrating one or a plurality of the peening pins in a center axis direction; rotating the one peening pin about a single rotation axis parallel to the center axis while the center axis of the one peening pin is offset from the rotation axis, when using the one peening pin; rotating the plurality of the peening pins about the rotation axis, when using the plurality of the peening pins; and moving the one or the plurality of the peening pins along the welding direction to peen the weld toe.
Also, in the needle-peening method, the plurality of the peening pins are arranged in a radial direction centered on the rotation axis.
Moreover, in the needle-peening method, the plurality of the peening pins are arranged in a circumferential direction centered on the rotation axis.
Overlapping defects can be prevented from being caused at a weld toe, a welding ripple at the weld toe can be flattened, and fatigue properties of a welded joint can be improved.
Conventionally, it has been considered that, when a radius of curvature of a weld toe is small, that is, 1.0 mm or less, stress concentration is difficult to be sufficiently relieved due to a sharp shape thereof. Thus, it has been considered that a radius of curvature of a cross section perpendicular to a welding direction of a distal end part of the peening pin needs to be increased to some degree, for example, to be equal to or larger than the radius of curvature of the weld toe to relieve stress concentration by peening the weld toe with a peening pin. However, there has been the risk that, if the weld toe is peened by a peening pin having a larger radius of curvature than that of the weld toe, an overlapping defect 47 at the weld toe may be caused by a plastic flow of a material as illustrated in
On the other hand, if the weld toe is peened along the welding direction by using a peening pin having a smaller radius of curvature than the radius of curvature of the weld toe, as illustrated in
Thus, as a result of examining a cause of fatigue of the welded joint again in detail, we found that the fatigue properties are deteriorated by a minute projection and depression, which is called a “welding ripple,” having a size equal to or smaller than 0.05 mm generated at the weld toe at the time of welding. Specifically, we found that a high-strength material having a tensile strength of 780 MPa grade or more is largely influenced by lowering of fatigue strength due to stress concentration on the weld toe so that an effect of improving the fatigue properties is increased by relieving the stress concentration.
Thus, we sought a method of relieving the shape of the weld toe without causing overlapping defects for the weld toe having a radius of curvature equal to or smaller than 1.0 mm, and flattening the welding ripple at the weld toe in peening the weld toe by the peening pin.
As a result, we found that, by peening the weld toe along the welding direction while rotating the peening pin having a radius of curvature smaller than the radius of curvature of the weld toe about a rotation axis offset from a center axis of the peening pin, the welding ripple at the weld toe can be flattened while preventing both of overlapping defects at the weld toe and overlapping defects at the peening mark end from being caused, and fatigue properties and productivity can be sufficiently improved.
The following describes a needle-peening method according to an example based on
Our needle-peening method in this example is performed, as illustrated in
At a distal end part 1a of the peening pin 1, a radius of curvature of a cross section perpendicular to the welding direction is equal to or larger than 0.05 mm and smaller than 1.00 mm. By setting the radius of curvature of the distal end part 1a in this range, a shape of minute projection and depression of the weld toe 19 can be relieved without being influenced by wear of the distal end part 1a caused by peening, and overlapping defects can be prevented from being caused at the weld toe 19 by peening.
In performing peening with the one peening pin 1 as illustrated in
In this way, by rotating the peening pin 1 about the rotation axis offset from the center axis of the peening pin 1, a peening process width is widened to peen and process the entire periphery of the weld toe 19, and the welding ripple at the weld toe 19 can be flattened. Due to this, preprocessing by a grinder and the like as disclosed in JP '140 is not required.
With the peening pin 1 in which the radius of curvature of the distal end part 1a is set to be in the range described above, a plastic deformation region in a thickness direction due to peening is a surface layer of about 0.05 mm of a processed portion of the welded joint 11. Due to this, a strain gradient in the thickness direction becomes large, a local large compressive residual stress is obtained on a surface of the processed portion, and the fatigue strength is improved. Additionally, the plastic deformation region in the thickness direction is shallow, that is, about 0.05 mm so that warping of sheet caused by the needle-peening processing is prevented.
In the related art, a peening pin having a radius of curvature equal to or larger than 1.00 mm has been used, but in our peening pin 1, the distal end part 1a thereof has a small radius of curvature equal to or larger than 0.05 mm and smaller than 1.00 mm. Due to this, a contact area with respect to the processed portion of the welded joint 11 becomes smaller so that it is possible to reduce a peening load applied to the peening pin 1 to generate a pressure to cause plastic deformation of the surface layer of the welded joint 11. Due to this, a tool that performs the peening process can be downsized compared to a conventional air-type peening or ultrasonic-type peening, and workability and productivity can be improved.
Furthermore, the peening process width can be widened by rotating the peening pin about the offset rotation axis so that it is possible to implement construction of securely peening the weld toe even in a welded joint in which a weld bead has an unstable shape or a curved shape. In performing peening while rotating the peening pin, a range of a portion that should be peened is at least about 0.5 mm toward a weld bead side and a base metal side from the weld toe as a center.
As a guideline for setting parameters, assuming that a frequency of peening pin vibration is fH [l/s], a rotation speed is f [l/s], and a radius of gyration (offset distance) is r [mm], the following relation may be satisfied:
0.5/2π≤f/fH≤2.0/2πr.
Assuming that a moving speed is v [mm/s], the following relation may be satisfied:
0.25f≤v≤2.5f.
As described above, it is possible to easily and remarkably improve the fatigue properties of the welded joint obtained by welding and joining high-strength materials. An effect obtained can be sufficiently given to automotive parts that are required to reduce the thickness and improve the fatigue properties.
In the above description, peening is performed while rotating the one peening pin 1. As other aspects of our methods, as exemplified in
In this way, by arranging and rotating the peening pins 1 to perform peening, a peening area can be enlarged, and a peening speed can be increased without increasing the peening load applied to the peening pins 1. Additionally, as illustrated in
The shape of the distal end part 1a of the peening pin 1 is not limited so long as the radius of curvature of the cross section perpendicular to the welding direction is equal to or larger than 0.05 mm and smaller than 1.00 mm. As the shape of the distal end part 1a, for example, a hemispherical shape, a semi-elliptical shape, a semi-cylindrical shape, an abbreviated semi-cylindrical shape, and the like can be used.
The welded joint 11 in the above description is a lap fillet welded joint obtained by lap fillet welding of the two pieces of sheet metal 13 and 15. However, our methods not only apply to the weld toe of the lap fillet welded joint, but also may be applied to a fillet welding joint such as a T-joint or a cruciform joint, a butt welding joint and the like. A welding method for the welded joint is not limited to arc welding, and our methods can be applied to a weld toe formed by any welding method. Furthermore, material of the sheet metal used as the base metal of the welded joint is not limited so long as the sheet metal is a thin plate.
An experiment was performed to confirm a working effect. The following describes the experiment. In this example, needle-peening processing was performed, by using a peening pin that performs peening while being rotated, on a weld toe of a weld bead in a welded joint obtained by lap fillet arc welding of two steel sheets. Subsequently, fatigue specimens were taken from the welded joint subjected to the needle-peening processing and the welded joint not subjected to the needle-peening processing by comparison, and a plane bending fatigue test was performed to evaluate a fatigue strength. Specific procedures and conditions are described below.
Two steel sheets 23 and 25 (300×140 mm) were cut out from a hot-rolled steel sheet having a thickness of 2.9 mm and a tensile strength of 980 MPa grade. The steel sheets 23 and 25 were fixed by a jig, and subjected to lap fillet arc welding to make a welded joint 21 (refer to
In this example, the needle-peening processing was performed by using a procedure described below. First, as illustrated in
In moving the peening pin 1 by the robot arm, first, the welded joint 21 as the first one was used, and teaching was performed for the robot arm assuming that a welding start part 27a of a weld bead 27 was a peening process start position, and a welding end part 27b was a peening process end position.
Next, based on the teaching, the first welded joint 21 was subjected to the needle-peening processing. Subsequently, the first welded joint 21 was replaced with the welded joint 21 as the second one, and the needle-peening processing was performed under the conditions used for the teaching for the first welded joint 21. By repeating this work, five welded joints 21 in total were made with the same welding conditions and needle-peening conditions.
In this way, four fatigue specimens were taken from each of the one welded joint 21 subjected to the needle-peening processing and the welded joint not subjected to the needle-peening processing by comparison, and a plane bending fatigue test was performed. Fatigue test conditions were set so that a repetition frequency was 15 Hz, and a stress ratio (a ratio between a minimum value and a maximum value of a stress loaded on the fatigue specimen) was 0 (pulsating). The number of cycles of loading the stress until a fatigue crack was caused in the fatigue specimen was measured, and the test was finished when the number of cycles reaches 3×106, which was assumed to be a fatigue limit.
The needle-peening processing was performed on the weld toe 29 of the made welded joint 21 by vibrating, by an electromagnetic tool at 100 Hz, the one peening pin 1 including the distal end part 1a in which the radius of curvature of the cross section perpendicular to the welding direction was 0.3 mm. Needle-peening processing conditions are indicated by Table 2.
In Table 2, No. 1 to No. 3 are related to the needle-peening processing conditions according to an example, and a moving speed, a radius of gyration (an offset distance between the center axis of the peening pin 1 and the rotation axis), and a rotation speed of the one peening pin 1 are changed. No. 4 indicates the needle-peening processing conditions for peening the weld toe without causing the one peening pin to be offset or rotated by comparison.
Next, in the welded joint that was made under the welding conditions indicated by Table 1, the three peening pins illustrated in
Assuming that the repetition frequency was 15 Hz, a load stress range was 650 MPa, and the stress ratio was 0 (pulsating), the number of cycles of loading the stress until the fatigue crack was caused in the fatigue specimen was measured, and the number of cycles of 3×106 was assumed to be the fatigue limit. Additionally, the cross section perpendicular to the welding direction of the weld toe after being subjected to the needle-peening processing was photographed, and presence/absence of generation of an overlapping defect due to peening by the peening pin and wear of the distal end part of the peening pin due to peening were observed and evaluated. Table 3 indicates the radius of curvature of the distal end part of the peening pin, generation of the overlapping defect, wear of the distal end part of the peening pin, and an evaluation result obtained by integrating these items.
According to Table 3, in No. 11 according to the comparative example, the radius of curvature of the distal end part was 0.03 mm, and the overlapping defect was not caused at the weld toe. However, peening could not be sufficiently performed along the welding direction because wear of the distal end part was hard so that the fatigue specimen to be used for the fatigue test could not be taken.
In No. 16 according to the comparative example, the radius of curvature of the distal end part was 1.00 mm, which was larger than the radius of curvature of the weld toe so that the overlapping defect was caused at the weld toe.
In contrast, in No. 12 to No. 15 in which the radius of curvature of the distal end part falls within our range, the overlapping defect was not caused at the weld toe, and a degree of wear of the distal end part of the peening pin was sufficiently low and favorable.
As described above, in No. 11 of Table 3, the needle-peening processing could not be continued because wear of the distal end part of the peening pin was hard so that a required number of fatigue specimens for evaluation could not be taken. In No. 16 according to the comparative example, the radius of curvature of the distal end part was 1.00 mm, which was larger than our preferable range so that the overlapping defect was caused at the weld toe, and the fatigue crack was caused at the number of cycles of about 1×105 to 1.4×105 as indicated by Table 3 described above.
In contrast, in No. 12 to No. 15 according to an example, a favorable result was obtained such that the fatigue life is the number of cycles of 2×105 to 10×105 compared to No. 16 according to the comparative example. A result was obtained such that, when the radius of curvature of the distal end part was increased in a range equal to or larger than 0.05 mm and smaller than 1.00 mm, the compressive residual stress working on a bottom of the peening mark formed by peening by the peening pin was increased so that the fatigue life tended to be further improved.
Furthermore, the needle-peening processing was performed on the welded joint that was made under the welding conditions indicated by Table 1 while causing the radius of curvature of the distal end part of the peening pin to be 0.3 mm, and changing the arrangement of the peening pins, the number of the peening pins, and the radius of gyration. The plane bending fatigue test was then performed on the fatigue specimen after being processed under conditions of the repetition frequency of 15 Hz, the load stress of 650 MPa, and the stress ratio of 0 (pulsating) to evaluate the fatigue life. In the needle-peening processing, it was assumed that the number of vibrations of the peening pin was 100 Hz, the moving speed was 80 cm/min, and the rotation speed was 7.5 times/s.
According to Table 4, the overlapping defect was not caused both in No. 21 to No. 24 in which the peening pins were arranged in the radial direction of the rotation axis, and in No. 25 and No. 26 in which the peening pins were arranged in the circumferential direction of the rotation axis. A favorable result of the fatigue life was obtained such that an average value of the number of cycles was high in all of No. 21 to No. 26 according to an example compared to the average value of the number of cycles of about 1.5×105 in conventional No. 4 illustrated in
The fatigue life was almost the same in No. 21 to No. 23 among which the radius of gyration was changed, the radius of gyration as the offset distance between the rotation axis and the center axis of the peening pin closest to the rotation center, and a favorable result was obtained under any condition.
We provide a needle-peening method that can relieve stress concentration on a weld toe, and can prevent overlapping defects from being caused.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2019-042366 | Mar 2019 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2019/043633 | 11/7/2019 | WO | 00 |
