CN102072877B - System and method for measuring residual stress in real time - Google Patents
System and method for measuring residual stress in real time Download PDFInfo
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Abstract
The invention relates to a system and a method for measuring residual stress in real time. The method comprises the following steps of: performing three-dimensional surface coordinate reconstruction on a test piece by three-dimensional digital image correlation, performing related research on a speckle image at the periphery of a hole before and after drilling the test piece, and calculating a three-dimensional displacement field before and after drilling; automatically feeding an electric spindle precisely through control over a stepping motor by a stepping motor controller and the translation of a worm gear and worm mechanism according to the drilling depth of the test piece; and calculating the residual stress of the test piece according to planar assumption of a drilling area of a curved surface by combining a theoretical formula for measuring the residual stress during drilling. The system can drill the hole precisely in real time, and measures the residual stress of the test piece with depth change in a stepping mode. The system and the method for measuring the residual stress have the advantages of real-time property, high precision, non-contact, whole-field displacement measurement, flexibility and convenience of operation, and the like.
Description
Technical field
The present invention relates to a kind of system of real-time borehole survey unrelieved stress and utilize the three-dimensional digital image correlation technique to measure unrelieved stress, this invention belongs to photo-measuring experimental mechanics, construction material, the deformation of member, three-dimensionalreconstruction and boring residual stress measurement field.
Background technology
Unrelieved stress is meant that the various external factor that produce stress still exist at material internal after removing, and keeps the stress of balance through self.The external factor that produces unrelieved stress has a lot, like temperature variation, materials processing, shot blast, surface treatment, phase transformation, separates out etc.Unrelieved stress directly influences the structure usability, and especially in engineering pipeline, welding residual stress directly influences the safe application performance of structure, and it can promote the material production stress corrosion crack, reduces fatigue behaviour and brittle failure drag, reduces physical dimension stability etc.Therefore, the unrelieved stress test is a needed important measuring technology in engineering and the research work.Current residual stress analysis method of supplying usefulness can have two big classifications by its essence.First kind residual stress analysis method is the stress relief method, promptly utilizes cutting that the unrelieved stress in the member is discharged, and calculates unrelieved stress according to cutting mode and the corresponding strain quantity that discharges.In engineering site was measured, the less relatively boring method of damage measured workpiece degree obtained more application.Boring method is measured the method that unrelieved stress is a kind of measurement unrelieved stress of half destruction, and this method damage is little, and measuring accuracy is higher, is widely used in Residual Stress of Welding Structure and measures.The theoretical foundation of boring method is based on the Kirsch problem of theory of elasticity, with near the unrelieved stress of the stress difference the aperture before and after the boring as boring release.Another kind of is the rerum natura method, promptly utilizes the material principle that physical property changes under stress to measure unrelieved stress.X-ray method for example, the neutron diffraction method, ultrasonic method (typically have patent of invention to have, be used for the method (Chinese invention patent ublic specification of application 98806517.7) of residual stress measurement) is pressed magnetic method etc.Rerum natura method mensuration unrelieved stress is commonly referred to as harmless residual stress analysis method, because in the mensuration process, need not damage measured workpiece, but because measuring technology is complicated, is subject to external condition and disturbs, so the engineering site application has big difficulty.The method of recent a kind of impact indentation obtains paying attention to; The variation that initial indentation method is based on stress induced material hardness proposes; Like a kind of residual stress measuring method (Chinese invention patent ublic specification of application 01106312.2), method of impact indentation assaying residual stress (Chinese invention patent ublic specification of application 93110137.9).
Unrelieved stress often utilizes boring method to combine the measuring method of foil gauge to measure in engineering; The technology of carrying out unrelieved stress through the method for boring also has a lot; For example a kind of method for measuring welding residual stress (Chinese invention patent ublic specification of application 200910014661.1); Unrelieved stress proving installation (Chinese invention patent ublic specification of application 200820090081.9) can satisfy most engineering survey in conjunction with foil gauge and boring method, but since foil gauge for responsive to temperature; The strain measurement precision depends on the technology of bonding; And boring centering is required very high, measuring process receives the influence of environment electromagnetics radiation etc. bigger, is not suitable for the measurement under the complex environment.
Summary of the invention
The purpose of this invention is to provide a kind of real-time borehole survey unrelieved stress system and method, this method is simple to operate, and the auto-feed keyhole degree of depth realizes that online in real time measures, and can improve in the past the limitation in digital picture measurement of correlation unrelieved stress again.
Technical scheme of the present invention is following:
A kind of real-time residual stress measurement system, it is characterized in that: this system comprises the electric main shaft that has drill bit, electric main shaft frequency modulator, a CCD camera, the 2nd CCD camera, computing machine, stepper motor, stepping motor control apparatus, electric main shaft translation driving device, cold light source, gridiron pattern scaling board, fixed flat planar, the test specimen secured adjusted device of " the boring residual stress measurement software for calculation that three-dimensional digital image is relevant " is installed; A described CCD camera and the 2nd CCD camera are installed on the camera adjustments support, and are connected with described computing machine through control line; Described electric main shaft translation driving device comprises turbine worm mechanism and stepping translation stage; The stepping translation stage is arranged on the turbine worm; The electricity main shaft is installed on the stepping translation stage through the translation stage link; The output shaft of stepper motor links to each other with scroll bar, and stepper motor drives the turbine worm translation mechanism and realizes moving axially of electric main shaft through stepping translation stage and translation stage link; Turbine worm mechanism, stepper motor, stepping motor control apparatus, electric main shaft frequency modulator, camera adjustments support and test specimen secured adjusted device all are fixed on the fixed flat planar.
A kind of real-time residual stress measuring method provided by the invention is characterized in that this method comprises the steps:
1) at first the unrelieved stress test specimen is placed on the test specimen stationary installation, open cold light source, light can evenly be loose in the test specimen surface; Through the height and the angle of camera adjustments bracket adjustment the one CCD camera and the 2nd CCD camera, and make that the prebored hole position can blur-free imaging, keep a CCD camera and the 2nd CCD camera position motionless then;
2) test specimen is taken off, utilized the gridiron pattern scaling board to demarcate the intrinsic parameter and outer parameter of a CCD camera and the 2nd CCD camera, described intrinsic parameter comprises focal length and photocentre, rotation matrix and translation matrix that described outer parameter is relative world coordinate system; In calibration process, rotate arbitrarily or mobile gridiron pattern scaling board, utilize a CCD camera and the 2nd CCD camera to take the view image of the different azimuth of at least three width of cloth scaling boards respectively, utilize the calibration algorithm calibrated and calculated to obtain the inside and outside parameter of camera then;
3) reinstall test specimen, adjustment test specimen regulating device and drill bit make bore position be in the camera view fully; Regulate the stepping translation stage, make bore position be in the images acquired center of a CCD camera and the 2nd CCD camera; Select different bit diameters as requested;
4) utilize a CCD camera and the 2nd CCD camera to take respectively to obtain hole before the speckle pattern on test specimen surface;
5) start electric main shaft translation driving device and make drill bit be close to prebored hole position on the test specimen,, regulate the rotating speed of drill bit, begin boring through regulating electric main shaft frequency modulator (11) according to the rotating speed of different materials for test setting drill bits;
6) make electric main shaft and drill bit away from the test specimen surface, utilize a CCD camera and the 2nd CCD camera to take near the speckle pattern of boring back boring respectively;
7) calculate: take four width of cloth images that obtain before and after will holing; Utilize " the boring residual stress measurement software for calculation that three-dimensional digital image is relevant " to carry out the three-dimensional digital image correlation computations; Obtain the displacement that boring method discharges; Import the inside and outside parameter of camera again, promptly calculate the size of unrelieved stress;
8) stepping residual stress measurement: stepped bore is set stepping amount, repeating step 3) to 7), calculate along the size distribution of test specimen depth direction unrelieved stress.
The present invention has the following advantages and the high-lighting effect: the system and method that the present invention proposes is based on non-contacting optics measurement of full field method, and the automatic keyhole degree of depth of combined high precision has realized real-time online boring noncontact measurement of full field; And simple to operate, can utilize that three-dimensional digital image is relevant obtains the microdeformation amount that unrelieved stress discharges, can the stepped bore degree of depth, measure the size of test specimen different depth unrelieved stress.
Description of drawings
Fig. 1 is the theory structure synoptic diagram of real-time residual stress measurement provided by the invention system.
The test specimen surface speckle image that Fig. 2 obtains for preceding first, second camera of boring is captured.
The test specimen surface speckle image that Fig. 3 obtains for first, second camera of boring back is captured.
Fig. 4 is the process flow diagram of real-time residual stress measuring method provided by the invention.
Among the figure: 1-unrelieved stress test specimen; The 2-drill bit; 3-electricity main shaft; 4-translation stage link; 5-stepping translation stage; 6-turbine worm translation mechanism; The 7-turbine worm drives and control device; 8-the one CCD camera; 9-the 2nd CCD camera; 10-stepper motor and control device; 11-electricity main shaft frequency modulator; The 12-computing machine; 13-test specimen secured adjusted device; The 14-cold light source; 15-gridiron pattern scaling board; The 16-fixed flat planar.
Embodiment
Further specify concrete structure of the present invention, principle of work and embodiment below in conjunction with accompanying drawing.
Real-time residual stress measurement provided by the invention system comprises drill bit 2, electric main shaft 3, electric main shaft frequency modulator 11, a CCD camera 8, the 2nd CCD camera 9, computing machine 12, stepper motor 7, stepping motor control apparatus 10, electric main shaft translation driving device, cold light source 14, gridiron pattern scaling board 15, fixed flat planar 16 and the test specimen secured adjusted device 13 of " the boring residual stress measurement software for calculation that three-dimensional digital image is relevant " is installed.The one CCD camera 8 and the 2nd CCD camera 9 are installed on the camera adjustments support, and are connected with described computing machine 12 through control line; Electricity main shaft translation driving device comprises turbine worm mechanism 6 and stepping translation stage 5; The stepping translation stage is arranged on the turbine worm; Electricity main shaft 3 is installed on the stepping translation stage through translation stage link 4; The output shaft of stepper motor links to each other with scroll bar, and stepper motor drives turbine worm translation mechanism 6 and realizes moving axially of electric main shaft through stepping translation stage and translation stage link 4; Turbine worm mechanism 6, stepper motor 7, stepping motor control apparatus 10, electric main shaft frequency modulator 11, camera adjustments support and test specimen secured adjusted device 13 all are fixed on the fixed flat planar 16.Unrelieved stress test specimen 1 is fixed and is positioned on the test specimen stationary installation 13, and a CCD camera 8 and the 2nd CCD camera 9 all place on the camera support, can freely regulate the height and the angle of camera through camera support.Drill bit 2 is installed on the electric main shaft 3, and electric main shaft 3 is fixedly linked through translation stage link 4 with stepping translation stage 5.Stepper motor 7 receives the control of stepper motor and control device 10.The rotating speed of the electric main shaft 3 of electricity main shaft frequency modulator 11 controls.
Measuring method of the present invention is following:
1) at first unrelieved stress test specimen 1 is placed on the test specimen stationary installation 13, open cold light source 14, light can evenly be loose in the test specimen surface; Through the height and the angle of camera adjustments bracket adjustment the one CCD camera 8 and the 2nd CCD camera 9, and make that the prebored hole position can blur-free imaging, keep a CCD camera 8 and the 2nd CCD camera 9 positions motionless then;
2) test specimen is taken off, utilized gridiron pattern scaling board 15 to demarcate the intrinsic parameter and outer parameter of a CCD camera 8 and the 2nd CCD camera 9, described intrinsic parameter comprises focal length and photocentre, rotation matrix and translation matrix that described outer parameter is relative world coordinate system; In calibration process, rotate arbitrarily or mobile gridiron pattern scaling board, utilize a CCD camera 8 and the 2nd CCD camera 9 to take the view image of the different azimuth of at least three width of cloth scaling boards respectively, utilize the calibration algorithm calibrated and calculated to obtain the inside and outside parameter of camera then;
3) reinstall test specimen, adjustment test specimen regulating device and drill bit make bore position be in the camera view fully; Regulate the stepping translation stage, make bore position be in the images acquired center of a CCD camera and the 2nd CCD camera; Select different bit diameters as requested;
4) utilize a CCD camera and the 2nd CCD camera to take respectively to obtain hole before the speckle pattern on test specimen surface;
5) starting electric main shaft translation driving device makes drill bit be close to prebored hole position on the test specimen; Set the rotating speed of drill bit according to different materials for test; Regulate the rotating speed of drill bit through regulating electric main shaft frequency modulator, set stepper motor and control simultaneously and adorn 10 stepping amount, begin boring; If once boring discharges, measure the unrelieved stress standard according to foil gauge, for thick test specimen, drilling depth is generally 1.2 times of bore diameter;
6) after the boring displacement is set, makes electric main shaft and drill bit, utilize a CCD camera and the 2nd CCD camera to take near the speckle pattern the boring of boring back respectively away from unrelieved stress test specimen surface; If the continuation stepped bore, then repeating step 4)～6);
7) calculate: take four width of cloth images that obtain before and after will holing; Utilize " the boring residual stress measurement software for calculation that three-dimensional digital image is relevant " to carry out three-dimensional digital image correlation computations (software copyright registration number: 2010SRBJ1724); Obtain the displacement that boring method discharges; Import the inside and outside parameter of camera again, promptly calculate the size of unrelieved stress;
8) stepping residual stress measurement: stepped bore is set stepping amount, repeating step 3) to 7), calculate along the size distribution of test specimen depth direction unrelieved stress.
The system that the present invention proposes is based on non-contacting optics measurement of full field method, and the automatic keyhole degree of depth of combined high precision can realize real-time borehole survey, reaches the purpose that real-time online is convenient for measuring unrelieved stress.The method of this boring stepping; Its theory can list of references (ASTM E837-08e1 Standard Test Method for Determining Residual Stresses by the Hole-Drilling Strain-Gage Method; ASTM international, United States).
Comprehensive its cardinal principle of native system is described below: based on the three-dimensional digital image correlation technique of binocular vision principle, through two camera inside and outside parameter about demarcating, obtain the world coordinates of test specimen surface characteristics point through the triangular methods reduction.Utilize the left camera image in boring back image as a reference; In residual stress measurement software, selecting the zone of the position of its 1.2 times of boring radius after the boring as calculating; The selection in this zone can be 1.1 sesquialters footpaths to 1.3 sesquialters footpath; If is plastic region according to the elastic properties of materials theory in 1.2 times of zones, then can select the zone is the radius region more than 1.4 times.With the left camera image in back of holing is reference picture, and taking the image that obtains with the hole right camera image in back and the preceding left and right sides camera of holing is target image, calculates the position of unique point in the respective image through the digital picture related algorithm.With the displacement of the 3-D view of unique point before and after the inside and outside parameter reduction boring of this result of calculation combining camera, import the unrelieved stress calibrating parameters of finite element, can calculate the size of test specimen unrelieved stress at last.
The borehole survey process instance; Selected test specimen is the interference fit aluminum test specimen of thick 10mm two annulus; Its unrelieved stress size calculates 150.5Mpa according to theoretical formula, and one, the adjustment light path; Bore position is accurately focused, make drill bit (the selection bit diameter is 2mm) on the normal of bore position.Two, take off test specimen, any at least three angle shot scaling boards are demarcated camera; Three, test specimen is installed, adjustment test specimen regulating device and drill head make bore position be in the camera view fully; Four, before the shooting boring, the test specimen speckle image, as shown in Figure 2, the test specimen surface speckle image that obtains for the preceding left and right sides camera of holing is captured.Five, the adjustment translation stage makes drill head near the test specimen position, step-wise displacement is set, hole (drilling depth is 2mm); Six, displacement is set, makes drill head, take test specimen surface, boring back speckle away from the test specimen surface, as shown in Figure 3, the test specimen surface speckle image that obtains for the preceding left and right sides camera of holing is captured; Whether seven, continue, stepped bore, disposable boring discharges residual stress measurement if no longer continuing boring; Eight, utilize " the boring residual stress measurement software for calculation that three-dimensional digital image is relevant " (software copyright registration number: 2010SRBJ1724), import picture, carry out the three-dimensional digital image correlation computations; Import the material for test nominal data, calculate unrelieved stress.The computation process of unrelieved stress can simply be described as down: utilize the relevant three-dimensional world coordinate of rebuilding test specimen surface, boring back each point of three-dimensional digital image, X
Wa, Y
Wa, Z
WaX wherein
Wa, Y
WaBe test specimen face internal coordinate system, Z
WaBe coordinate, calculate the three-dimensional coordinate X of the same characteristic features point on the preceding surface, the world of boring equally perpendicular to the test specimen surface
Wb, Y
Wb, Z
Wb, the displacement that discharges owing to boring so does
ΔX＝X
Wa-X
Wb
ΔY＝Y
Wa-Y
Wb
ΔZ＝Z
Wa-Z
Wb
Wherein, Δ X, Δ Y are that unrelieved stress boring discharges caused in-plane displacement; Δ Z is that unrelieved stress boring discharges caused acoplanarity displacement, according to theory boring residual stress measurement formula, calculates the unrelieved stress size by displacement field; List of references (Nelson; D., A.Makino, T.Schmidt; Residual Stress Determination Using Hole Drilling and 3DImage Correlation.Experimental Mechanics, 2006.46 (1): p.31-38.).The unrelieved stress size that calculates at last is 143.6Mpa, and error is in 5%.
Claims (2)
1. real-time residual stress measurement system, it is characterized in that: this system comprises electric main shaft (3), electric main shaft frequency modulator (11), a CCD camera (8), the 2nd CCD camera (9) that has drill bit (2), computing machine (12), stepper motor (7), stepping motor control apparatus (10), electric main shaft translation driving device, cold light source (14), gridiron pattern scaling board (15), fixed flat planar (16) and the test specimen secured adjusted device (13) that " the boring residual stress measurement software for calculation that three-dimensional digital image is relevant " is installed; A described CCD camera (8) and the 2nd CCD camera (9) are installed on the camera adjustments support, and are connected with described computing machine through control line; Described electric main shaft translation driving device comprises turbine and worm translation mechanism (6) and stepping translation stage (5); The stepping translation stage is arranged on the turbine and worm; Electricity main shaft (3) is installed on the stepping translation stage through translation stage link (4); The output shaft of stepper motor links to each other with scroll bar, and stepper motor drives turbine and worm translation mechanism (6) and realizes moving axially of electric main shaft (3) through stepping translation stage and translation stage link (4); Turbine and worm translation mechanism (6), stepper motor (7), stepping motor control apparatus (10), electric main shaft frequency modulator (11), camera adjustments support and test specimen secured adjusted device (13) all are fixed on the fixed flat planar (16).
2. one kind is adopted the real-time residual stress measuring method of system according to claim 1, it is characterized in that this method comprises the steps:
1) at first unrelieved stress test specimen (1) is placed on the test specimen secured adjusted device (13), open cold light source (14), light can evenly be loose in the test specimen surface; Through the height and the angle of camera adjustments bracket adjustment the one CCD camera (8) and the 2nd CCD camera (9), and make that the prebored hole position can blur-free imaging, keep a CCD camera (8) and the 2nd CCD camera (9) position motionless then;
2) test specimen is taken off; Utilize gridiron pattern scaling board (15) to demarcate the intrinsic parameter and outer parameter of a CCD camera (8) and the 2nd CCD camera (9); Described intrinsic parameter comprises focal length and photocentre, rotation matrix and translation matrix that described outer parameter is relative world coordinate system; In calibration process, rotate arbitrarily or mobile gridiron pattern scaling board; Utilize a CCD camera (8) and the 2nd CCD camera (9) to take the view image of the different azimuth of at least three width of cloth scaling boards respectively, utilize the calibration algorithm calibrated and calculated to obtain the inside and outside parameter of camera then;
3) reinstall test specimen, adjustment test specimen secured adjusted device and drill bit make bore position be in the camera view fully; Regulate stepping translation stage (5), make bore position be in the images acquired center of a CCD camera (8) and the 2nd CCD camera (9); Select different drill bit (2) diameter as requested;
4) utilize a CCD camera (8) and the 2nd CCD camera (9) to take respectively to obtain hole before the speckle pattern on test specimen surface;
5) start electric main shaft translation driving device and make drill bit (2) be close to prebored hole position on the test specimen,, regulate the rotating speed of drill bit, begin boring through regulating electric main shaft frequency modulator (11) according to the rotating speed of different materials for test setting drill bits (2);
6) make electric main shaft (3) and drill bit (2) away from test specimen (1) surface, take near the speckle pattern of boring back boring respectively;
7) calculate: take four width of cloth images that obtain before and after will holing; Utilize " the boring residual stress measurement software for calculation that three-dimensional digital image is relevant " to carry out the three-dimensional digital image correlation computations; Obtain the displacement that boring method discharges; Import the inside and outside parameter of camera again, promptly calculate the size of unrelieved stress;
8) stepping residual stress measurement: stepped bore is set stepping amount, repeating step 3) to 7), calculate along the size distribution of test specimen depth direction unrelieved stress.
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