CN103630564A - Measure method for residual stress of high-speed train body - Google Patents
Measure method for residual stress of high-speed train body Download PDFInfo
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Abstract
A measure method for residual stress of high-speed train body comprises the following steps: (1) calibrating a X-ray residual stress measuring apparatus; (2) selecting a measure area, processing the surface of the measure area to satisfy the measure requirements; and (3) selecting a measure point, utilizing a X-ray diffraction method to perform residual stress measure on the selected surface and outputting measure results. By utilizing the surface processing technology and combining with the calibration technology, the measure error is guaranteed to be in a reasonable scope, the repeatability is high, the measure result error is controlled at +/- 5 MPa, and the method has the characteristics of being lossless and rapid; the method helps to mitigate the work intensity of on-site work personnel; and 1.8 million kilometer road test on the train body and members thereof both subjected to the surface processing technology verifies that the surface processing technology has no damage to the train body, so that the traffic safety is guaranteed.
Description
Technical field
The present invention relates to a kind of method of utilizing X-ray diffraction method to measure unrelieved stress, particularly a kind of residual stress measuring method for high-speed train body.
Background technology
China's bullet train manufacturing technology has striden into world's rank of advanced units, and the safe reliability of bullet train is the stable operation of protection train, promotes bullet train manufacturing technology to the important deciding factor of depth research and development.
Unrelieved stress is one of key factor affecting bullet train safe reliability, it not only affects the manufacturing dimension precision of bullet train, cause body construction distortion, and the existence of unrelieved stress also can cause the existence of weld defects (as crackle) etc., and accelerate the failure modes such as the stress corrosion of bullet train in operational process, corrosion fatigue, dynamic load fatigue.Unrelieved stress size and the distribution of Measurement accuracy high-speed train body structure, to performances such as the various machineries of evaluation body construction, mechanics, accurate instruction is produced, and dimensional accuracy, stress corrosion resistant ability and the fatigue strength and the fatigue reliability that improve body construction are significant.
Conventional residual stress measuring method has Blind Hole Method, sliver method, supercritical ultrasonics technology, X-ray diffraction method, neutron diffraction method etc.Wherein Blind Hole Method, sliver are owned by France in destructive measurement method, cannot on high-speed train body, effectively be applied.Supercritical ultrasonics technology can realize Non-Destructive Testing, but test undulatory property is larger, cannot accurately detect size and the distribution of unrelieved stress for the less position of stress amplitude, and bad measurement repeatability cannot meet the needs of high-speed train body structure residual stress measurement.Neutron diffraction method need be set up large-scale atomic pile as generation source, cannot be applied in actual detection.X-ray diffraction method principle is the most ripe, and the method can not produce and destroy member, can not introduce extra extra-stress yet, at aerospace field, has obtained comparatively successfully applying.
The manufactured materials of China's bullet train is comprised of materials such as carbon steel, stainless steel, aluminium alloy, magnesium alloys, when selecting X-ray diffraction method to carry out unrelieved stress test, need select process for treating surface and measuring technique according to different test conditions.
Summary of the invention
Fundamental purpose of the present invention is to address the above problem and is not enough, provides a kind of measuring method simple, and measuring accuracy is high, and can realize high-speed train body residual stress measuring method harmless, Quick Measurement.
For achieving the above object, technical scheme of the present invention is:
A high-speed train body residual stress measuring method, comprises the steps:
(1) X ray unrelieved stress testing apparatus is demarcated;
(2) selected test zone, processes the surface of test zone, it is met and measure requirement;
(3) selected test point, utilizes X-ray diffraction method to carry out unrelieved stress test to selected surface, and outputs test result.
Further, in described step (1), the strong bar such as select as tensile sample, adopt the theoretical calculating of drawing stress, electrical measuring method, X ray unrelieved stress testing apparatus to carry out Measurement and Computation to the unrelieved stress of the strong bar such as described at least simultaneously, and then X ray unrelieved stress testing apparatus is demarcated.
Further, in described step (2), surface treatment specifically comprises carries out weld reinforcement removal to the surface of test zone, recycling electropolishing equipment effects on surface carries out cleaning polishing, remove extra-stress layer, to the removal due to extra-stress layer, cause the measuring error that stress relief causes to be revised simultaneously.
Further, when the surface of test zone is cleaned, selecting saturated NaCl solution is polishing fluid.
Further, the surfaceness of test zone is less than 10 μ m.
Further, in the test process of described step (3), also comprise that take the surface level of test surfaces is benchmark, the step of utilizing focusing pin automatically to focus.
Further, in the test process of described step (3), the test point in test zone is carried out to line sweep or face scanning, to measure the size of unrelieved stress and to distribute.
Further, in described step (3), after test finishes, output test result and comprise two-dimentional cloud atlas or the three-dimensional cloud atlas of residual stress distribution.
Content to sum up, high-speed train body residual stress measuring method of the present invention, utilize process for treating surface, in conjunction with calibration technique, guarantee measuring error in the reasonable scope, repeatable high, within can be controlled at ± 5MPa of test result deviation, and have harmless, feature fast, within the Measuring Time of each point can be controlled at 3min-10 min according to different measurement requirements, slow down field personnel's working strength, car body materials and member thereof after this process for treating surface is processed, after the road test of 1,800,000 kilometers, verified that this process for treating surface is to car body not damaged, can guarantee traffic safety.
The present invention not only can be applied to high-speed train body, but also can be applied among the Large-Scale Equipment manufacturing industry such as Aero-Space, boats and ships technique, auto industry, Nuclear Power Industry, boilers and pressure vessel, national defense industry.
Accompanying drawing explanation
Fig. 1 is the strong bar structural representations such as the present invention;
Fig. 2 is the side direction view of Fig. 1;
Fig. 3 is aluminium alloy calibration result schematic diagram;
Fig. 4 is line sweep schematic diagram;
Fig. 5 is line sweep stress envelope;
Fig. 6 is face scanning schematic diagram.
As shown in Figures 1 to 6, wait strong bar 1, mother metal 2, weld seam 3, test point 4.
Embodiment
Below in conjunction with accompanying drawing and embodiment, the present invention is described in further detail:
High-speed train body residual stress measuring method of the present invention, for high-speed train body production, assembling, adjusting, reprocess, operation on line, roll the overall process real-time follow-up tests such as the test platform dry run of shaking.Be applicable to the car body that the materials such as aluminium alloy, magnesium alloy, stainless steel and carbon steel are made.
The parts that can be used for measuring comprise a car (trailer) cab, underframe, side wall, roof, headwall, the large parts such as middle car (motor-car) underframe, side wall, roof, headwall and car load outside surface, inside surface.Test mode can comprise the former primary state of section bar, welding state, adjusting state, reprocess state, sandblast state, shot-peening state, overhaul state at different levels (as three grades repair, Pyatyi is repaiied etc.).
The present embodiment be take aluminum alloy bodywork as example, and residual stress measuring method is elaborated, and specifically comprises the steps:
(1) X ray unrelieved stress testing apparatus is demarcated
First under laboratory condition, by grade, hale and stretch rating test, and adopt theoretical calculating of electrical measuring method, X-ray diffraction method and drawing stress to demarcate X ray unrelieved stress equipment, may be controlled to ± 7Mpa of measuring error, may be controlled to ± 5Mpa of measuring repeatability deviation.
X-ray diffraction scalp acupuncture is found the measurement parameter matching with it in the measurement technological parameter system of pedigree to different measurement materials.For aluminum alloy materials, find 130 °-150 ° and 145 ° of-165 ° of diffraction peaks, mate different peak location methods, as the Automatic-searchings such as parabolic method, gravity model appoach, Pearson VII, Cauchy method, Gauss method are optimum, measure technological parameter.
It measures the pedigreeization design of technological parameter, by grade, hale rating test technology and the two-way stretch rating test technology of stretching, on the basis of process for treating surface, X ray nondestructive measurement body construction welding residual stress technological parameter has been carried out to pedigreeization design.For aluminum alloy materials, angle of diffraction is 156.31 °, and the diffraction time shutter is 2 seconds, and diffraction exposure frequency 20 times, angle of diffraction are set as 7 (maximum can be set 21 angle of diffraction) Angle measurement pendulum angles for ± 3 ° (maximums can be set as ± 6 °).
The method of the strong bar stretching rating tests such as the A5083P-O aluminium alloy of take is example detailed description:
The method that adopts WD-20KE cupping machine to carry out tension test demarcation, the strong bar 1 such as has designed based on tensile sample.
As depicted in figs. 1 and 2, the useful area of the strong bar 1 such as design is: A=a * b, wherein, within the scope of A5083P-O aluminum alloy materials limit of elasticity, length a will extend along with the increase of tensile force.For guaranteeing that tensile force F stepless action is in area A, the length of the retaining part of design extension rod piece is greater than 1.2 times of tension test machine grip holder length, and waiting useful area and the retaining part design transition groove of strong bar 1, to guarantee the transmission of power and to be uniformly distributed.
According to the known σ=F/A of Principles of Statics; Wherein: F is axle power (pulling force), and A is cross-sectional area.Meridional stress value in the time of can trying to achieve stretching according to statics formula.
As shown in Figure 1, post 10 foil gauges waiting on strong bar 1 tensile sample, in pasted foil gauge, foil gauge 1# ~ 6# institute veneer is X ray test face, and 7# ~ 10# foil gauge is for supervising tested one side.In tension test process, test is loaded as 0 ~ 17.28KN, and draw speed is 0.1 mm/min.
Table 1 X-ray diffraction method unrelieved stress test parameter
Unrelieved stress numerical value etc. strong bar 1 is calculated by the theoretical calculating of drawing stress, electrical measuring method, the built-in mathematical methods such as Pearson, Cauchy of X ray unrelieved stress tester system respectively, has shown calibration result when test material is A5083P-O aluminium alloy in Fig. 3.
(2) surface treatment
The concrete implementation step of surface treatment method is as follows:
2-1, visual examination
First check A5083P-O aluminum alloy surface, see defects such as whether having crackle, pore, slag inclusion, and check whether there is weld reinforcement.
2-2, surface finish and weld reinforcement are removed
Weld reinforcement and mother metal mechanical relationship are inconsistent, and have weld ripples, uneven surface, and for the higher material of angle of diffraction (as aluminium alloy), measuring error is larger, should note avoiding uneven surface.The position of general first selected test in this measuring method, until mother metal district, processes out a panel region of continuous formation from weld seam center to welding heat affected zone, and measurement point requires to be arranged in this region according to measuring.
As checked in rear discovery measured zone, there is above defect and weld reinforcement, adopt air sander to remove reinforcement, guarantee that weld seam and mother metal are in same level line, and adopt surface roughness tester to carry out roughness inspection to aluminum alloy surface.
When polished thing roughness is greater than 10 μ m, need to carry out pre-service to polished thing, to reduce roughness to the impact of follow-up unrelieved stress test result (roughness is larger, and unrelieved stress measuring accuracy is poorer).
Preprocess method is as follows: if surfaceness is greater than 20 μ m, be less than 50 μ m, first adopt 500 object sand paper to adopt 1000 object sand paper to carry out grinding, until roughness is less than 10 μ m again; If surfaceness is greater than 10 μ m and is less than 20 μ m, adopt 1000 object sand paper to carry out grinding, until roughness is less than 10 μ m; If surfaceness is greater than 50 μ m, adopt emery wheel paper (described emery wheel paper is arranged on abrasive machine) to carry out grinding until surfaceness is less than 50 μ m, adopt again 500 object sand paper to adopt again 1000 object sand paper to carry out grinding, until roughness is less than 10 μ m.
2-3, test surfaces clean
The point of State selective measurements should be avoided test as far as possible and shows defect and collide with scuffing vestige.
After the surface of test zone meets roughness and requires, be configured to the polishing fluid that saturated NaCl solution is principal ingredient, and polishing fluid is added to self-loopa, electropolishing equipment that concentration ratio is constant, aluminum alloy surface is carried out to electropolishing.Remove surface and oil contaminant, oxide skin and rust staining, make test zone expose clean metal surface, during on-the-spot test, need main protection, prevent the test surfaces that dust and ejecta pollution are cleaned.
Polished thing through above-mentioned steps polishing: surface presents metallic luster, without furvous; Surface flawless, pore etc. affect the defect of measuring accuracy.
Electrolytic polishing process: 20 ℃ of electric current 10A, voltage 5V, polish temperatures, polishing time 15min;
In polishing process with polishing fluid contact material: glass fibre.
2-4, extra-stress layer are removed
Air sander, when removing weld reinforcement, more than the extra-stress layer depth that aluminum alloy surface is produced can reach 150 μ m, utilizes electropolishing to eliminate extra-stress layer.For eliminating the error that causes stress relief to cause due to polishing, compensating module RESERVE SIMULATION is set in measuring system, this module can be calculated voluntarily according to the glossing parameter of pedigree, to the removal due to extra-stress layer, cause the measuring error that stress relief causes to be revised, its cardinal principle is that the correction of skew occurs for Bragg angle on depth direction, and correction formula is:
, wherein
, 2 θ in formula
tr-Bragg angle after revising; 2 θ
ob-test gained Bragg angle; The z-degree of depth; The image standard angle of diffraction of θ-1/2; ψ-inclination angle; μ-correction factor.Through revised Bragg angle, the Bragg angle of replacing former test gained is carried out to Stress calculation, and final or revised stress value.Stress value is after calibration sample, and measuring error is ± 7Mpa that measuring repeatability deviation is ± 5Mpa.
Evaluate process for treating surface except above-mentioned rating test, can be by observing the variation of stress value and diffraction peak halfwidth.From stress value angle, consider, when stress value reaches steady state (SS), can think that extra-stress layer removes; From the angle of diffraction peak halfwidth, consider, when diffraction peak halfwidth reduces gradually and tends towards stability along with the increase of layer depth, can think that extra-stress layer removes.
Process for treating surface in this measuring method can guarantee that metal material surface roughness is in 10 μ m, and then meets measurement requirement.
For 5,6,7 line aluminium alloys and 2 line aluminium alloys for bullet train, magnesium alloy, stainless steel, the bullet trains such as carbon steel form glossing parameter and the glossing scheme of pedigree by various types of materials.The through engineering approaches treatment technology that this process for treating surface forms verifies that it is to aluminum alloy bodywork not damaged after 1,800,000 kilometers of real vehicle operations of bullet train.
Surface treated material surface, surfaceness can be controlled in 10 μ m, for the material that has surface imperfection (shortcoming), can characterize out from macroscopic view.
(3) adopt X-ray diffraction method to measure the unrelieved stress of material or member
Utilize X ray unrelieved stress tester to carry out unrelieved stress detection to car body materials or member, for aluminum alloy materials, the Measuring Time of each measurement point can require to be set as 3min ~ 10min according to different measurements, with integral body, improves measuring speed.
High-speed train body unrelieved stress is harmless, quick in order to meet, precision etc. measured requirement, in the present embodiment, in X ray unrelieved stress tester by the secondary development of VC++ language residual stress measurement software XRDWIN EDIT, it has the parallel interface that can compile, and can control many unrelieved stress equipment simultaneously.
In the present embodiment, line sweep and face scan function in X ray unrelieved stress tester, have been increased, as shown in Fig. 4, utilize X-ray diffraction measuring instrument to carry out line sweep to measuring the test point of the test zone of material or member, centered by weld seam 3, test point 4 is extended on mother metal 2 to both sides, and the stress distribution result that line sweep draws as shown in Figure 5.Test point 4 distribution plans of face scanning as shown in Figure 6, in test zone, test point uniform spreading is arranged, test point is carried out to face scanning, and this technology can be within the scope of the whole piece continuum of setting, by setting requirement, automatically measure unrelieved stress size and distribute, in measuring process, can export two-dimentional cloud atlas and three-dimensional cloud atlas, measurement result is accurate, stress distribution shows that image is attractive in appearance, clear, can mutually verify with numerical simulation result.
In measuring process, adopt Autofocus Technology, take aluminum alloy surface surface level as benchmark, adopt focusing pin automatically to focus, focusing be from being controlled at 20mm ± 0.1mm, reduction measuring error as much as possible.
Through CRH2 type bullet train, the test of CRH3 type bullet train entity structure, calibration technique, Numerical Simulation and compare with blind hole measuring result, measurement result trend is consistent, numerical value coincide, and measuring technique is reliable.
Adopt this Novel high-speed train car body residual stress measurement technology to be applied to carry out stress measurement on the production domesticization high-speed train bodies such as Chinese CRH2, CRH3, test result precision is high, and measuring method is reliable.It is blank that Chinese high-speed train body residual stress measurement has been filled up in realization of the present invention, for Chinese high-speed train body is produced, manufacture provides basic data to support, has great economic worth and far-reaching social effect.In this technology, process for treating surface and measuring technique not only can be applied to high-speed train body but also can be applied among the Large-Scale Equipment manufacturing industry such as Aero-Space, boats and ships technique, auto industry, Nuclear Power Industry, boilers and pressure vessel, national defense industry.
As mentioned above, given scheme content, can derive similar technical scheme by reference to the accompanying drawings.In every case be the content that does not depart from technical solution of the present invention, any simple modification, equivalent variations and the modification above embodiment done according to technical spirit of the present invention, all still belong in the scope of technical solution of the present invention.
Claims (8)
1. a high-speed train body residual stress measuring method, is characterized in that, comprises the steps:
(1) X ray unrelieved stress testing apparatus is demarcated;
(2) selected test zone, processes the surface of test zone, it is met and measure requirement;
(3) selected test point, utilizes X-ray diffraction method to carry out unrelieved stress test to selected surface, and defeated
Go out test result.
2. high-speed train body residual stress measuring method according to claim 1, it is characterized in that: in described step (1), the strong bar such as select as tensile sample, adopt the theoretical calculating of drawing stress, electrical measuring method, X ray unrelieved stress testing apparatus to carry out Measurement and Computation to the unrelieved stress of the strong bar such as described at least simultaneously, and then X ray unrelieved stress testing apparatus is demarcated.
3. high-speed train body residual stress measuring method according to claim 1, it is characterized in that: in described step (2), surface treatment specifically comprises carries out weld reinforcement removal to the surface of test zone, recycling electropolishing equipment effects on surface carries out cleaning polishing, remove extra-stress layer, to the removal due to extra-stress layer, cause the measuring error that stress relief causes to be revised simultaneously.
4. high-speed train body residual stress measuring method according to claim 3, is characterized in that: when the surface of test zone is cleaned, selecting saturated NaCl solution is polishing fluid.
5. high-speed train body residual stress measuring method according to claim 3, is characterized in that: the surfaceness of described test zone is less than 10 μ m.
6. high-speed train body residual stress measuring method according to claim 1, is characterized in that: in the test process of described step (3), also comprise that take the surface level of test surfaces is benchmark, the step of utilizing focusing pin automatically to focus.
7. high-speed train body residual stress measuring method according to claim 1, is characterized in that: in the test process of described step (3), the test point in test zone is carried out to line sweep or face scanning, to measure the size of unrelieved stress and to distribute.
8. high-speed train body residual stress measuring method according to claim 7, is characterized in that: in described step (3), after test finishes, output test result and comprise two-dimentional cloud atlas or the three-dimensional cloud atlas of residual stress distribution.
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| CN105043443A (en) * | 2015-07-03 | 2015-11-11 | 大连交通大学 | Vehicle body stress testing device for high speed train and work method thereof |
| CN105333981A (en) * | 2015-11-10 | 2016-02-17 | 中信重工机械股份有限公司 | Method of precisely detecting residual stress of oversized and overweight cast steel gear |
| CN106289899A (en) * | 2016-07-25 | 2017-01-04 | 中航工业哈尔滨轴承有限公司 | A kind of bearing parts residual stress is along the preparation method of layer depth distribution detection sample |
| CN107407606A (en) * | 2015-03-05 | 2017-11-28 | 株式会社神户制钢所 | Residual stress estimates method and residual stress estimating device |
| CN107748026A (en) * | 2017-09-06 | 2018-03-02 | 北京航空航天大学 | A kind of synchronous across yardstick residual stress detection method |
| CN109187179A (en) * | 2018-08-16 | 2019-01-11 | 东南大学 | A kind of biaxial tensile test calibration adjustment method based on cross testpieces |
| CN113218571A (en) * | 2020-10-26 | 2021-08-06 | 中国航空工业集团公司北京长城计量测试技术研究所 | Residual stress standard test block setting and tracing method |
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| CN107407606A (en) * | 2015-03-05 | 2017-11-28 | 株式会社神户制钢所 | Residual stress estimates method and residual stress estimating device |
| CN107407606B (en) * | 2015-03-05 | 2020-09-22 | 株式会社神户制钢所 | Residual stress estimation method and residual stress estimation device |
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| CN105333981A (en) * | 2015-11-10 | 2016-02-17 | 中信重工机械股份有限公司 | Method of precisely detecting residual stress of oversized and overweight cast steel gear |
| CN105333981B (en) * | 2015-11-10 | 2017-11-10 | 中信重工机械股份有限公司 | A kind of method of accurate detection super-big and overweight cast steel gear residual stress |
| CN106289899A (en) * | 2016-07-25 | 2017-01-04 | 中航工业哈尔滨轴承有限公司 | A kind of bearing parts residual stress is along the preparation method of layer depth distribution detection sample |
| CN107748026A (en) * | 2017-09-06 | 2018-03-02 | 北京航空航天大学 | A kind of synchronous across yardstick residual stress detection method |
| CN109187179A (en) * | 2018-08-16 | 2019-01-11 | 东南大学 | A kind of biaxial tensile test calibration adjustment method based on cross testpieces |
| CN109187179B (en) * | 2018-08-16 | 2021-06-11 | 东南大学 | Biaxial tension test calibration debugging method based on cross-shaped test piece |
| CN113218571A (en) * | 2020-10-26 | 2021-08-06 | 中国航空工业集团公司北京长城计量测试技术研究所 | Residual stress standard test block setting and tracing method |
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