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<p>Residual stresses, induced during manufacturing due to solidification shrinkage and phase transformations in large-scale structural components of precision machine tools, may significantly compromise the components’ accuracy and service life. Thermal aging, widely employed for stress relief, requires rigorous optimization of its process parameters to maximize effectiveness. This study investigates the evolution of residual stresses in HT300(ASTM Class 30/EN-GJL-300) cast iron crossbeams during thermal aging using a heating rate of 50–55&#xa0;°C/h, a holding temperature of 550&#xa0;°C, and a cooling rate of 15–20&#xa0;°C/h. A thermomechanical-coupled finite element analysis, validated by non-destructive magnetic measurements (with a mean relative error &lt;15%), was employed. Analysis of variance (ANOVA) was conducted to quantify the influence of each parameter, while response surface methodology (RSM) with central composite design (CCD) was used to analyze parameter interactions. A multi-objective non-dominated sorting whale optimization algorithm (NSWOA) was developed to minimize both residual stress on the guide rail surface and total process time, yielding a Pareto-optimal set of process parameters. Compared to the baseline process, the optimized scheme achieved a 5.27% reduction in global residual stress levels and a 5.40% reduction at critical locations, while also improving stress uniformity. These results provide a quantitative basis for selecting optimal parameters in the industrial thermal aging of large cast iron structures, thereby enhancing dimensional stability and operational reliability.</p>

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Residual Stress Control in HT300 Machine Tool Crossbeams: A Multi-Objective Optimization Approach for the Thermal Aging Process

  • 期刊论文

  • 发表日期：

    2026年2月11日

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  • Jihao Duan,
  • Penggang Ma,
  • Gaochen Zhang,
  • Xindou Han,
  • Feng Gao,
  • Yan Li

摘要

Residual stresses, induced during manufacturing due to solidification shrinkage and phase transformations in large-scale structural components of precision machine tools, may significantly compromise the components’ accuracy and service life. Thermal aging, widely employed for stress relief, requires rigorous optimization of its process parameters to maximize effectiveness. This study investigates the evolution of residual stresses in HT300(ASTM Class 30/EN-GJL-300) cast iron crossbeams during thermal aging using a heating rate of 50–55 °C/h, a holding temperature of 550 °C, and a cooling rate of 15–20 °C/h. A thermomechanical-coupled finite element analysis, validated by non-destructive magnetic measurements (with a mean relative error <15%), was employed. Analysis of variance (ANOVA) was conducted to quantify the influence of each parameter, while response surface methodology (RSM) with central composite design (CCD) was used to analyze parameter interactions. A multi-objective non-dominated sorting whale optimization algorithm (NSWOA) was developed to minimize both residual stress on the guide rail surface and total process time, yielding a Pareto-optimal set of process parameters. Compared to the baseline process, the optimized scheme achieved a 5.27% reduction in global residual stress levels and a 5.40% reduction at critical locations, while also improving stress uniformity. These results provide a quantitative basis for selecting optimal parameters in the industrial thermal aging of large cast iron structures, thereby enhancing dimensional stability and operational reliability.