System and Method for Controlled Vibration Stress
Relief of Metal Parts with Residual Internal Stresses
Claudiu NICOLA, Adrian VINTILĂ, Marcel NICOLA, Viorica VOICU, Maria Cristina NIŢU, Marian DUȚĂ
Research, Development Division for Electric Equipment and Energy Efficiency
National Institute for Research, Development and Testing in Electrical Engineering-ICMET
Craiova, România
nicolaclaudiu@icmet.ro, adrian_vintila@icmet.ro, marcel_nicola@icmet.ro
programe@icmet.ro, cristinanitu@icmet.ro, general_manager@icmet.ro
Abstract— The paper presents a new method and a new
equipment for the dimensional stabilization of metal parts using
controlled mechanical vibration technique. The dimensional
stabilization through vibrations consists in using controlled
vibrations to reduce the residual stress in metal parts or
structures. The mechanical characteristics of metal parts have
two basic components: the functional mechanical strength and
dimensional stability in time. These two components are
interrelated to each other. The method is based on a new
algorithm for adaptive vibration, depending on the behavior of
the metal parts. The equipment for the stress relief through
vibrations is a complex process computer system including a
process computer, a frequency converter, an eccentric vibrator, a
flexible shaft, an induction motor and an acceleration transducer.
The system reduces the level of residual internal stresses in a
certain metal part, following its own stress relief algorithm
implemented in LabVIEW environment.
Keywords—stress-relief, mechanical vibration, software
application, LabVIEW, dimensional stability.
I. INTRODUCTION
The dimensional stability is conditioned by the unstable
residual stress. These unstable residual stresses lead to
cracking and dimensional changes in metal parts [2]-[5]. The
problem consists in eliminating as much as possible of the
unstable internal stress, without affecting the stable stress
condition. The reduction in the residual stress is achieved by
creating variable stress in the metal part. The part undergoes
vibration at resonant frequency for a given period depending
on certain mechanical characteristics of the part. Vibrating
activates latent internal energy caused by internal stress, thus
accelerating the rearrangement process of atomic planes (the
systematic displacement) and the internal energy dissipation in
the material. An accelerated or artificial ageing of the material
can be said to occur [10], [11], [13].
Dimensional stabilization through vibration consists in
using controlled vibration to reduce the residual stress in metal
parts or structures [12]. This method is not a complete
replacement of the method of stress relief by thermal cycle,
but it is an efficient alternative to dimensional stabilization
and stress relief of parts in any production stage, with no
structural changes and with no influence on mechanical
properties and fatigue strength in the material. The method
consists in applying low frequency mechanical vibration, with
controlled amplitude, in the part undergoing treatment.
978-1-4673-8562-6/16/$31.00©2016 European Union
Application of vibration leads to a change in the positions of
unstable atoms moving within very short distances in order to
stabilize each crystal and the whole structure at the same time.
The vibration stress relief results in achieving a more stable
structure with low microscopic residual stress [14], [15], [16].
This treatment can be applied both to ferrous and non-ferrous
parts; it can also be applied during the welding process, in
order to avoid cracking. Practically this method does not
require any limits regarding the weight of the part undergoing
treatment.
There are currently several types of vibration stress relief
pieces of equipment [17], [18]. All these pieces of equipment
are based on the material intended for stress relieving
undergoing controlled mechanical vibration in terms of
frequency and amplitude.
The system carries out verification of the degree of
vibratory stress relief in metal parts, and this process is
achieved by primarily checking resonance peaks stability
within the frequency range of the parts, both as amplitude and
displacement [19], [20]. In other words, through vibration, the
resonance peaks within the frequency range of the parts are
moving and changing in amplitude. When these changes stop,
we can say that the part is dimensionally stabilized.
II. DESCRIPTION OF THE SYSTEM
The system presented in this paper in Figure 1 is a
monitoring and control system for the resonance peaks within
the frequency range of the metallic parts, carried out by
process computer. The vibratory stress relief process is
computer achieved using the software application developed
with LabVIEW programming [1] based on the algorithm
shown in Figure 2.
The hardware architecture of the stress relief system is
shown in Figure 3. DAQ (Data Acquisition) is simply the
process of bringing a real-world signal, such as voltage, into
the computer, for processing, analysis, storage or other data
control. A physical phenomenon represents the real world
signal that we measure. In order to optimize the characteristics
of a system in terms of performance, handling capacity and
cost, the relevant subsystems can be combined together.
Analog data is generally acquired and transformed into the
digital form for the purpose of processing, transmission and
display.
 Rapid advances in Personal Computer (PC) hardware and
software technologies have resulted in easy and efficient
adoption of PCs in various precise measurement and complex
control applications.
A PC based measurement or control application requires
conversion of real world analog signal into digital format and
transfer of digitized data into the PC. A data acquisition
system that performs conversion of analog signal to digital
data and the digital data to analog signal is interfaced to a PC
to implement the functions of measurement and control
instrumentation applications [4], [5].
Fig. 3. The hardware architecture of the stress relief system.
Fig. 1. System for controlled vibration stress relief.
amplifiers to convert their output to useful levels. Honeywell
in-line charge amplifiers are versatile and convenient solutions
for the use of charge-mode piezoelectric transducers.
Fig. 2. The algorithm underlying the developed software application.
The hardware components of the stress relief system are:
• Process computer;
• Control and monitoring module: DAQ NI USB-6009,
signal conditioning system Model CA2 Honeywell,
frequency inverter Model D700-SC Mitsubishi;
• Acceleration transducer Model MAQ14 Honeywell;
• Three-phase asynchronous motor;
• Eccentric vibrator;
• Rubber buffers.
DAQ NI USB-6009 specifications:
− 8 analog inputs (14-bit, 48 kS/s);
− 2 static analog outputs (12-bit); 12 digital I/O; 32-bit
counter;
− Bus-powered for high mobility; built-in signal
connectivity
− OEM version available;
− Compatible with LabVIEW, LabWindows™/CVI, and
Measurement Studio for Visual Studio .NET.
Charge-mode piezoelectric transducers require charge
Charge Amplifier Honeywell Model CA2 specifications:
− Input voltage: ±15 V dc or 24 V dc to 32 V dc;
− Input current: 20 mA;
− Sensitivity: Programmable (0.05 mV/pc to 6.4
mV/pc);
− Input range: 780 pc to 100000 pc;
− Output: ±5 V RMS maximum;
− Frequency response: 3 Hz to 30 kHz (-3 db);
− Time constant, Model CA2: 50 ms.
 The MAQ14 is a self-generating piezoelectric transducer software also prevents a programmer from having to carry out
which has no internal electronics and requires no external register-level programming or complicated commands to
power for operation. access the hardware functions.
Accelerometer Model MAQ14 specifications: The application software is based on state machines. A
state machine is programming architecture that can be used to
− Dynamic range: 1000 G; implement any algorithm that can be explicitly described by a
− Sensitivity: 50 pC/G; state diagram or flowchart. It introduces a way to create a
− Transverse sensitivity: Less than 5 %; program such that it responds to user events (such as key
− Temperature sensitivity: 0.145/°F; strokes and mouse events) or in-state calculation (such as
− Frequency range: 1 Hz to 10 kHz; comparing system variables). This architecture provides a
− Amplitude linearity: Better than 1 % linearity distinct advantage to using a sequential architecture that uses
− Mounted base resonance: 18 kHz. data dependency to force execution in exactly the same way
every time.
The three phase asynchronous electric motors are simple,
reliable and have a low cost, for this reason the choice for Our application software generates a report which is an
these motors for industrial application will be highly essential part of a professional application. Reports must
prevalent. contain all the information that the user wants. In addition,
reports must look professional and be carefully formatted. The
Since the power supply frequency is usually constant at LabVIEW Report Generation Toolkit for Microsoft Office is a
50Hz, the motor speed is constant and can be modified for library of flexible, easy-to-use VIs for programmatically
various applications by changing the structure of the winding. creating and editing Microsoft Word and Excel reports from
After choosing the speed, the motor always operates at LabVIEW.
constant speed, for example approximately 3000 rpm or 1500
rpm. The application interface software is developed in a menu-
based system for easy and efficient management of vibratory
The solution for this problem consists in using a frequency stress relief phases and is presented in Figures 4-7.
converter, which is a device converting the constant voltage
and the power supply frequency into variable voltage with
variable frequency. This converter is installed between the
power supply and the motor [6], and allows the continuous
adjustment of the speed, turning a standard single winding
motor into a flexible actuator mechanism, with adjustable
speed. The speed of the connected motor can be modified
continuously by changing the converter frequency and output
voltage.
The eccentric vibrator is produced by ICMET Craiova and
has a welded, robust frame, with a fastening lug, providing
increased operating safety. The fastening of the vibrator on the
part undergoing treatment is achieved using bulky catches.
The rubber buffers isolate the part mechanically, allowing its
vibration at maximum amplitude.
Fig. 4. The interface for scanning part.
III. DESCRIPTION OF THE SOFTWARE APPLICATION
The application’s development software is LabVIEW,
which is a powerful programming graphical environment,
highly used for signal acquisition, measurement analysis and
data presentation, providing flexibility to traditional
programming languages and at the same time a user-friendly
interface. LabVIEW works on a data flow model in which
information within a LabVIEW program, called a virtual
instrument (VI), flows from data sources to data sinks
connected by wires [8].
The software transforms the PC and the data acquisition
hardware into a complete data acquisition, analysis, and
presentation tool. Without the software to control or drive the
hardware, the data acquisition device does not work properly.
Driver software is the layer of software for easy
communication with the hardware. It forms the middle layer
between the application software and the hardware. The driver Fig. 5. The interface for stress-relief part.

Fig. 6. The interface for the acceleration signal analysis before the stress-
relief of the part.
Fig. 7. The interface for the report generation with comparative acceleration
waveform graph.
IV. CONCLUSIONS
The controlled vibration stress-relief equipment is
portable, and can be used for parts in any size, shape or weight
achieved through welding or casting. Small parts can be
treated by fastening to a vibration plate. This method is ideal
for the applications requiring critical size parts, which would
require very large ovens for thermal stress-relief.
The advantages of the equipment are:
• It reduces the distortions during and after mechanical
processing and applies to a wide range of metals;
• It lowers the risk of cracking during welding;
• It does not affect the mechanical properties;
• Several parts can be treated at a time;
• The treatment can be applied in the point where the
mechanical processing is carried out;
• It consumes a fraction of the energy required by the
thermal stress-relief process;
• It applies to a wide range of internal voltage parts.
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