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研究生：	程士銓 Cheng, Shih-Chuan
論文名稱：	結合X光繞射感測之干涉配合與振動應力消除於金屬成形件殘留應力控制與尺寸穩定性之研究 Residual Stress Control and Dimensional Stability in Metal Forming Components by Press-Fitting and Vibratory Stress Relief with X-ray Diffraction Sensing
指導教授：	李榮顯 Lee, Rong-Shean
學位類別：	博士 Doctor
系所名稱：	工學院 - 機械工程學系 Department of Mechanical Engineering
論文出版年：	2026
畢業學年度：	114
語文別：	英文
論文頁數：	126
中文關鍵詞：	殘留應力、干涉配合、振動應力消除、X光繞射感測、尺寸穩定性
外文關鍵詞：	residual stress, press-fitting, vibratory stress relief, X-ray diffraction sensing, dimensional stability
相關次數：	點閱：12 下載：0
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本研究針對金屬成形組裝件於產品品質試驗中所發現之振動品質變異現象，探討其殘留應力演變與尺寸穩定性之關聯，並建立一套兼具問題導向與實驗驗證之研究架構。首先，透過 DFMEA 將異常現象界定為組裝後幾何穩定性不足之問題；其次，運用 TRIZ 與 Effects Database 進行問題抽象化與解決方向分析，據以確認殘留應力鬆弛與再分佈為造成尺寸變異之關鍵因素。基於此，本研究提出結合干涉配合與共振式振動應力消除之方法，並以 X 光繞射作為主要感測與評估工具。
實驗材料為深抽低碳鋼組件，藉由不同干涉配合應變條件進行組裝，再施以共振激振之振動應力消除處理。殘留應力量測採用 X 光繞射 sin²ψ 法，並輔以繞射峰半高寬(FWHM)分析，作為評估晶格畸變與微應變變化之輔助指標，同時以垂直度量測評估尺寸穩定性。研究結果顯示，干涉配合可於配合界面附近造成局部塑性變形，並有效改變原有殘留應力分佈，使直接配合區之殘留應力明顯降低；然而，不同區域因受結構拘束與應力傳遞影響，其應力重分佈行為具有明顯區域差異。經振動應力消除後，各量測位置之殘留應力進一步獲得鬆弛與重新分佈，且繞射峰半高寬呈下降趨勢，顯示材料內部晶格畸變與微應變相關效應有所降低。
在尺寸穩定性方面，較高干涉應變條件之試件於振動處理後呈現較小之垂直度變化，顯示其具有較佳之幾何穩定性。綜合而言，本研究證實結合干涉配合、共振式振動應力消除與 X 光繞射感測，可作為金屬成形組裝件殘留應力控制與尺寸穩定性評估之有效方法；同時亦說明，以 DFMEA、TRIZ 與 Effects Database 所建構之問題形成架構，有助於系統性連結工程異常、應力鬆弛機制與尺寸穩定性改善。

This study investigates residual stress evolution and dimensional stability in assembled metal forming components, focusing on vibration quality variation observed during product quality testing. A problem-oriented and experimentally validated framework was established. DFMEA was used to define the abnormal phenomenon as insufficient geometric stability after assembly. TRIZ and the Effects Database were then applied to abstract the problem and identify residual stress relaxation and redistribution as key factors causing dimensional variation. Based on this framework, this study proposes a method combining press-fitting and resonant vibratory stress relief, with X-ray diffraction as the primary sensing and evaluation tool.
Deep-drawn low-carbon steel components were assembled under different interference strain conditions and then treated by resonant vibratory stress relief. Residual stress was measured using the X-ray diffraction sin²ψ method. Full width at half maximum (FWHM) analysis was used as a supplementary indicator for evaluating changes in lattice distortion and microstrain, while perpendicularity measurement was used to assess dimensional stability. The results showed that press-fitting produced localized plastic deformation near the fitting interface and modified the original residual stress distribution, resulting in clear stress reduction in the direct fitting region. However, stress redistribution varied by location because of structural constraint and stress transmission. After vibratory stress relief, residual stress was further relaxed and redistributed. The decreasing FWHM trend also suggested reduced lattice distortion and microstrain-related effects.
Specimens with higher interference strain showed smaller perpendicularity changes after vibration treatment, indicating better geometric stability. Overall, combining press-fitting, resonant vibratory stress relief, and X-ray diffraction sensing provides an effective method for residual stress control and dimensional stability evaluation in assembled metal forming components. The DFMEA-, TRIZ-, and Effects Database-based framework also offers a systematic approach for connecting engineering abnormalities, stress relief mechanisms, and dimensional stability improvement.

摘要  i
Abstract  ii
Acknowledgements  iii
List of Contents  iv
List of Tables  vi
List of Figures vii
Nomenclature  ix
Chapter 1 . Introduction  1
1 Background  1
2 Motivation  2
3 Objectives  4
4 Dissertation Organization  5
Chapter 2 . Problem Formulation and Theoretical Background  7
1 Problem Identification and Solution Development Framework  7
1.1 Problem Definition by DFMEA  10
1.2 Specific Problem and Model of Problem in TRIZ through Root Cause Analysis 12
1.3 Model of Solutions in TRIZ and EDB-based Search  15
1.4 Specific Solutions Adopted in This Study  19
2 Residual Stress in Metal Forming Components  22
3 Residual Stress Measurement and Evaluation by XRD  25
3.1 Bragg’s Law and the sin²ψ Method  26
3.2 FWHM as an Indicator of Microstructural Change  30
4 Vibratory Stress Relief and Resonant Excitation  34
4.1 Fundamentals of Vibratory Stress Relief  34
4.2 Natural Frequency Identification and Resonant Excitation in Vibratory Stress Relief 36
4.3 Residual Stress Relief Mechanism of Vibratory Stress Relief  38
5 Press-Fitting and Its Influence on Residual Stress and Dimensional Stability 40
6 Research Gap 43
Chapter 3 . Materials, Experimental Setups and Methods  45
1 Materials and Specimen Configuration  46
2 Experimental Setup  49
2.1 Press-fitting Setup  49
2.2 Residual Stress Measurement by XRD  50
2.3 Resonance Frequency Sensing Setup  52
2.4 Vibratory Stress Relief Setup  53
2.5 Perpendicularity Measurement Setup  55
3 Experimental Procedure  57
3.1 Residual Stress Measurement Before Press-fitting and VSR  59
3.2 Press-fitting Procedure  61
3.3 Vibratory Stress Relief Procedure  63
3.4 Residual Stress and Perpendicularity Measurement After VSR  64
Chapter 4 . Results and Discussion  66
1 Global Response of the Press-fitted Workpiece Under Resonant Excitation  66
1.1 Dynamic Consistency of the Assembled Specimens 67
1.2 Selection of the Resonant Treatment Condition  69
2 Region-dependent Stress Redistribution After Press-fitting and VSR  71
2.1 Remote Redistribution Region  71
2.2 Constraint-dominated Transitional Region  76
2.3 Direct Interference Region  81
3 Microstructural Evidence of Stress Relaxation  86
4 Two-stage Stress-relief Mechanism of the Combined Process  87
4.1 First-stage Stress Modification Induced by Press-fitting  87
4.2 Second-stage Redistribution Induced by Resonant VSR  90
4.3 Overall Two-stage Stress-relief Mechanism of the Combined Process  91
5 Relationship Between Residual Stress State and Dimensional Stability  92
5.1 Geometric Response After VSR Under Different Interference Strains  93
5.2 Perpendicularity as an Indicator of Residual Stress Stabilization  95
6 Determination of the Most Favorable Interference Condition  96
6.1 Comparison of the Viewpoint of Local Stress Relief  97
6.2 Comparison of the Viewpoint of Dimensional Stability  98
6.3 Selection of the Optimal Condition Based on Combined Criteria  100
7 Concluding Remarks  100
Chapter 5 . Conclusions and Future Works  102
1 Conclusions  102
2 Limitations and Future Works  104
REFERENCES  105
Appendix A. Complete Vibration Records of the Product Quality Test  109
Appendix B. Complete EDB Query Results for Shape Stability  113
                                    

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