ABSTRACT Much research has focused on residual stress detection, analysis and elimination for alloy materials. There is however limited work considering residual stress in gray cast iron materials (HT200, 250, 300, 350) which are commonly used in heavy machine tool components. Herein an experimental program is undertaken to quantify the influence of typical machine tool production processes (casting, treatments, machining) on component residual stress. In addition, for a select component element (a guideway mounting surface), an extended measurement program tracks residual stress and surface deviations over a two-year period, quantifying the time-dependent behavior of production-induced stresses during initial in-service conditions. The experimental program establishes the relationship between material carbon content and component residual stress, with greater carbon content resulting in less residual stress. For the aging treatments (heating, vibration, natural aging), the program quantifies and ranks the achievable stress reductions (68.74%, 36.83%, 29.1%, respectively). Finally, the extended measurement program demonstrates that within 2 months of production, greater than 99% of process-induced residual stress has been released and surface deviation is less than 0.5 μm per month.

中文翻译：

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灰铸铁制造过程的残余应力分析

摘要 许多研究集中在合金材料的残余应力检测、分析和消除方面。然而，考虑到灰铸铁材料（HT200、250、300、350）中的残余应力，这些工作是有限的，这些材料通常用于重型机床部件。在此进行了一个实验程序，以量化典型机床生产过程（铸造、处理、机加工）对部件残余应力的影响。此外，对于选定的组件元件（导轨安装表面），扩展的测量程序在两年内跟踪残余应力和表面偏差，量化初始使用条件期间生产引起的应力的时间相关行为。实验程序建立了材料含碳量与部件残余应力的关系，含碳量越大，残余应力越小。对于时效处理（加热、振动、自然时效），该程序对可实现的应力降低进行了量化和排序（分别为 68.74%、36.83%、29.1%）。最后，扩展测量程序表明，在生产后的 2 个月内，超过 99% 的工艺引起的残余应力已经释放，表面偏差每月小于 0.5 微米。