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Residual stresses and hardening depth measurements - an on line approach to mechanical part 100% production testing

Objective

The objective of the project is to develop solutions based on non-conventional electromagnetic techniques (controlled-signal pulsed eddy currents, anisotropic magnetic permeability, Barkhausen noise), which are the most favourable to on-line implementation. These solutions will be based on parameter combinations of proven diagnostic reliability and measuring procedures applicable to on-line testing.
The project resulted in two techniques the first, electromagnetic permeability based one, able to supply consistent information on the residual stress state beneath the surface; the second, eddy current based one, able to predict at which depth a given hardness value is positioned.

Many mathematical simulations were operated and innovative data treatment used.

An important application of artificial intelligence was pursued in the field of non destructive testing: a prototype of neural network for non destructive evaluation was also implemented.

Two equipments, implementing the addressed techniques were prototyped and successfully tested.
The continued effort towards product quality improvement in the automotive industry has identified the need for reliable on-line non-destructive testing techniques that enable evaluation according to product specifications, the execution of local heat and /or mechanical treatments on critical components such as crankshafts, camshafts and gears. Required performances include characterization of surface hardness and residual stress states, independent of initial charge variability (priority themes 2.2.1 2.2.2 2.2.3 4.1.1).

A prototype system with automated evaluation capabilities will assembled and used for experimental validation in shop environment. A user-orientated flexible design will allow operation by non specialist personnel and enable different industrial end users to address their own specific problems. On-line feedback information to the process will thus become possible with further benefits in terms of reduction in finished product scraps and in related costs.

Coordinator

Iveco Fiat SpA
Address
Via Puglia 35
10156 Torino
Italy

Participants (5)

Centro Informazioni Studi ed Esperienze SpA
Italy
LABEIN
Spain
Renault
France
Address
9-11 Avenue Du 18 Juin 1940
92500 Rueil-malmaison
TU DORTMUND UNIVERSITY
Germany
Address

Dortmund
VOLKSWAGEN AG
Germany
Address

Braunschweig