CN103630564B - High-speed train body residual stress measuring method - Google Patents
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Abstract
The present invention relates to a kind of high-speed train body residual stress measuring method, comprise the steps: that X-ray residual stress test equipment is demarcated by (1)；(2) selected test zone, processes the surface of test zone so that it is meet measurement requirement；(3) selected test point, utilizes X-ray diffraction method that selected surface is carried out residual stress test, and outputs test result.The present invention utilizes process for treating surface, in conjunction with calibration technique, ensureing measurement error in the reasonable scope, repeatable high, test result deviation can control within ± 5MPa, and there is feature lossless, quick, slowing down field personnel's working strength, the car body materials after this process for treating surface processes and component thereof, after the road performance test of 1,800,000 kilometers, demonstrate this process for treating surface to car body not damaged, it can be ensured that traffic safety.<!--1-->
Description
Technical field
The present invention relates to a kind of method utilizing X-ray diffraction method to measure residual stress, particularly to 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 security reliability of bullet train is protection train stable operation, promotes the bullet train manufacturing technology important deciding factor to depth research and development.
Residual stress is one of key factor affecting bullet train security reliability, it not only affects the manufacture dimensional accuracy of bullet train, body construction is caused to deform, and the existence of residual stress also results in the existence of weld defect (such as crackle) etc., and accelerate the failure modes such as bullet train stress corrosion in running, corrosion fatigue, dynamic load fatigue.Accurately measure residual stress size and the distribution of high-speed train body structure, to evaluating the performances such as the various machineries of body construction, mechanics, accurate instruction produces, and improves the dimensional accuracy of body construction, stress corrosion resistant ability and fatigue strength and fatigue reliability is 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, it is impossible to effectively applied on high-speed train body.Supercritical ultrasonics technology can realize Non-Destructive Testing, but test undulatory property is relatively big, cannot accurately detect size and the distribution of residual stress, bad measurement repeatability, it is impossible to meet the needs of high-speed train body structure residual stress measurement for the position that stress amplitude is less.Neutron diffraction method need to set up large-scale atomic pile as occurring source, it is impossible to is applied in actually detected.X-ray diffraction method principle is the most ripe, and component will not be produced and destroy by the method, also will not introduce extra additional stress, obtain the most successfully applying at aerospace field.
The manufacture material of China's bullet train is made up of materials such as carbon steel, rustless steel, aluminium alloy, magnesium alloys, when selecting X-ray diffraction method to carry out residual stress test, need to select process for treating surface and the technology of measurement according to different test conditions.
Summary of the invention
Present invention is primarily aimed at solution the problems referred to above and deficiency, it is provided that a kind of measuring method is simple, and measuring accuracy is high, and can realize the high-speed train body residual stress measuring method of measurement lossless, quick.
For achieving the above object, the technical scheme is that
A kind of high-speed train body residual stress measuring method, comprises the steps:
(1) demarcating X-ray residual stress test equipment, different materials of measuring is found matched optimum measurement technological parameter measuring of pedigree by X-ray diffraction scalp acupuncture in technological parameter system；
(2) selected test zone, the surface of test zone is processed, it is made to meet measurement requirement, surface process specifically includes the surface to test zone and carries out weld reinforcement removal, recycling electrobrightening equipment is carried out polishing to surface, removes additional stress layer, arranges compensating module in measurement system, glossing parameter according to pedigree calculates voluntarily, is modified the measurement error causing Stress Release to cause due to the removal of additional stress layer；
(3) selected test point, utilizes X-ray diffraction method that selected surface is carried out residual stress test, and outputs test result.
Further, in described step (1), the strong bar such as selection is as tensile sample, at least while use tensile stress Theoretical Calculation, electrical measuring method, X-ray residual stress test equipment that the residual stress of the strong bar such as described is tested and calculated, and then X-ray residual stress test equipment is demarcated.
Further, when being carried out the surface of test zone, selecting saturated NaCl solution is polishing fluid.
Further, the surface roughness of test zone is less than 10 μm.
Further, in the test process of described step (3), also include on the basis of the horizontal plane of test surfaces, utilize focusing pin automatically to carry out the step focused.
Further, in the test process of described step (3), the test point in test zone is entered line scan or Surface scan, to measure size and the distribution of residual stress.
Further, in described step (3), after test terminates, output test result and include the two-dimentional cloud atlas of residual stress distribution or three-dimensional cloud atlas.
To sum up content, high-speed train body residual stress measuring method of the present invention, utilize process for treating surface, in conjunction with calibration technique, ensure measurement error in the reasonable scope, repeatable high, test result deviation can control within ± 5MPa, and have lossless, quickly feature, the measurement time of each point can control within 3min-10min according to different measurement requirement, slow down field personnel's working strength, car body materials after this process for treating surface processes and component thereof, after the road performance test of 1,800,000 kilometers, demonstrate this process for treating surface to car body not damaged, may insure that traffic safety.
The present invention can be applied not only to high-speed train body, can also 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 lateral view of Fig. 1；
Fig. 3 is aluminium alloy calibration result schematic diagram；
Fig. 4 is that line scans schematic diagram；
Fig. 5 is that line scans stress envelope；
Fig. 6 is Surface scan schematic diagram.
As shown in Figures 1 to 6, strong bar 1, mother metal 2, weld seam 3, test point 4 are waited.
Detailed description of the invention
With detailed description of the invention, the present invention is described in further detail below in conjunction with the accompanying drawings:
High-speed train body residual stress measuring method of the present invention, for high-speed train body production, assembling, adjusting, reprocesses, line runs, rolls the overall process real-time tracking tests such as test platform dry run of shaking.It is applicable to the car body that the materials such as aluminium alloy, magnesium alloy, rustless steel and carbon steel are made.
The parts that can be used for measuring include a car (trailer) drivers' cab, underframe, side wall, roof, headwall, the big parts such as middle car (motor-car) underframe, side wall, roof, headwall and car load outer surface, inner surface.Test mode can include the original state of section bar, welding state, adjusting state, reprocess state, sandblasting state, shot-peening state, overhaul state at different levels (as three grades repair, Pyatyi is repaiied).
Residual stress measuring method, as a example by aluminum alloy bodywork, is described in detail by the present embodiment, specifically includes following steps:
(1) X-ray residual stress test equipment is demarcated
The most in laboratory conditions, the strongly tensile rating test such as pass through, and using electrical measuring method, X-ray diffraction method and tensile stress Theoretical Calculation that X-ray residual stress equipment is demarcated, measurement error may be controlled to ± 7Mpa, and measurement reproducibility deviation may be controlled to ± 5Mpa.
Different materials of measuring is found matched measurement parameter measuring in technological parameter system of pedigree by X-ray diffraction scalp acupuncture.For aluminum alloy materials, find 130 °-150 ° and 145 ° of-165 ° of diffraction maximums, mate different peak location methods, as the Automatic-searching optimums such as parabolic method, centroid method, Pearson VII, Cauchy method, Gauss method measure technological parameter.
It measures pedigreeization design of technological parameter, strongly tensile rating test technology and the biaxial tension rating test technology such as passes through, and on the basis of process for treating surface, X-ray nondestructive measurement body construction welding residual stress technological parameter has carried out pedigreeization design.For aluminum alloy materials, the angle of diffraction is 156.31 °, diffraction time of exposure is 2 seconds, and diffraction exposure frequency 20 times, the angle of diffraction are set as that 7 (maximum can set 21 angle of diffraction) Angle measurement pendulum angles are as ± 3 ° (maximum may be set to ± 6 °).
The method of the strong bar such as detailed description stretching rating test as a example by A5083P-O aluminium alloy:
Use the WD-20KE cupping machine method that carries out tension test demarcation, the strong bar 1 such as devise based on tensile sample.
As depicted in figs. 1 and 2, the effective area of the strong bar 1 such as design is: A=a × b, wherein, in A5083P-O aluminum alloy materials elastic limits, the increase along with tensile force is extended by length a.For guarantee tensile force F stepless action on area A, the length of the retaining part of design extension rod piece is more than 1.2 times of tension test machine grip holder length, and is waiting effective area and the retaining part design transition groove of strong bar 1, to ensure the transmission of power and to be uniformly distributed.
σ=F/A is understood according to Principles of Statics；Wherein: F is axle power (pulling force), A is cross-sectional area.Longitudinal stress value when can try to achieve stretching according to statics formula.
As it is 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, 7#～10# foil gauge is used to supervision and is test for one side.During tension test, test is loaded as 0～17.28KN, and draw speed is 0.1mm/min.
Table 1X ray diffraction method residual stress test parameter
Calculated by mathematical methods such as built-in Pearson, the Cauchy of tensile stress Theoretical Calculation, electrical measuring method, X-ray residual stress test instrument system respectively etc. the residual stress numerical value of strong bar 1, Fig. 3 showing, test material is calibration result during A5083P-O aluminium alloy.
(2) surface processes
It is as follows that surface treatment method is embodied as step:
2-1, visual examination
First check for A5083P-O aluminum alloy surface, see defects such as whether there is crackle, pore, slag inclusion, and check for weld reinforcement.
2-2, surface finish and weld reinforcement are removed
Weld reinforcement is inconsistent with mother metal mechanical relationship, and has weld ripples, uneven surface, and for the material (such as aluminium alloy) that angle of diffraction is higher, measurement error is bigger, it should be noted that avoid uneven surface.In this measuring method, the position of general first selected test, until mother metal district from Weld pipe mill to welding heat affected zone, processes out a panel region of continuous formation, measures point and arranges in this region according to measurement requirement.
After checking, find measured zone exists disadvantages described above and weld reinforcement, then use air sander to remove reinforcement, it is ensured that weld seam and mother metal are in same level line, and use surface roughness tester that aluminum alloy surface is carried out roughness inspection.
When polished thing roughness is more than 10 μm, need polished thing is carried out pretreatment, to reduce the roughness impact (roughness is the biggest, and residual stress test precision is the poorest) on follow-up residual stress test result.
Preprocess method is as follows: if surface roughness is less than 50 μm more than 20 μm, the most first use the sand paper of 500 mesh to use the sand paper of 1000 mesh to carry out grinding again, until roughness is less than 10 μm；If surface roughness less than 20 μm, then uses the sand paper of 1000 mesh to carry out grinding more than 10 μm, until roughness is less than 10 μm；If surface roughness is more than 50 μm, emery wheel paper (described emery wheel paper is arranged on abrasive machine) is then used to carry out grinding until surface roughness is less than 50 μm, the sand paper using 500 mesh again uses the sand paper of 1000 mesh to carry out grinding again, until roughness is less than 10 μm.
2-3, test surfaces clean
Select the point measured should avoid test as far as possible and show defect and the scuffing vestige that collides with.
After the surface of test zone meets roughness requirements, the configuration polishing fluid with saturated NaCl solution as main component, and polishing fluid is added self-loopa, electrobrightening equipment that concentration ratio is constant, aluminum alloy surface is carried out electrobrightening.Remove surface and oil contaminant, oxide skin and rust staining, make test zone expose the metal surface of cleaning, during on-the-spot test, need main protection, prevent dust and the cleaned test surfaces of ejecta pollution.
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: electric current 10A, voltage 5V, polish temperature 20 DEG C, polishing time 15min；
With polishing fluid contact material in polishing process: glass fibre.
2-4, additional stress layer are removed
Air sander is when removing weld reinforcement, and the additional stress layer depth producing aluminum alloy surface can reach more than 150 μm, utilizes electrobrightening to eliminate additional stress layer.For eliminating the error causing Stress Release to cause due to polishing, compensating module RESERVESIMULATION is set in measurement system, this module can calculate voluntarily according to the glossing parameter of pedigree, the measurement error causing Stress Release to cause due to the removal of additional stress layer is modified, its cardinal principle is that the correction of skew occurs for Bragg angle on depth direction, and correction formula is:Wherein2 θ in formulatrBragg angle after-correction；2θob-test gained Bragg angle；The z-degree of depth；The image standard diffraction angle of θ-1/2；ψ-inclination angle；μ-correction factor.The Bragg angle replacing former test gained is carried out Stress calculation by the Bragg angle after being corrected, and finally obtains revised stress value.Stress value is after calibration sample, and measurement error is ± 7Mpa, and measurement reproducibility deviation is ± 5Mpa.
Evaluation process for treating surface, can be by observing stress value and the change of diffraction maximum halfwidth in addition to above-mentioned rating test.Consider from stress value angle, when stress value reaches steady statue it is believed that additional stress layer has been removed；From the point of view of diffraction maximum halfwidth, when diffraction maximum halfwidth along with when the increase of layer depth is gradually reduced and tends towards stability it is believed that additional stress layer has been removed.
Process for treating surface in this measuring method ensure that metal material surface roughness, within 10 μm, and then meets measurement requirement.
For bullet train 5,6,7 line aluminium alloys and 2 line aluminium alloys, magnesium alloy, rustless steel, the bullet train such as carbon steel forms 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 is formed verifies that it is to aluminum alloy bodywork not damaged after 1,800,000 kilometers of real vehicles of bullet train run.
Surface treated material surface, surface roughness can control within 10 μm, for there being the material of surface defect (shortcoming), it is possible to from macroscopically characterizing.
(3) X-ray diffraction method is used to measure material or the residual stress of component
Utilizing X-ray residual stress test instrument that car body materials or component are carried out residual stress detection, for aluminum alloy materials, each measurement time measuring point can be set as 3min～10min according to different measurement requirement, improves measuring speed with entirety.
For meeting the measurement requirement such as lossless, quick, the precision of high-speed train body residual stress, in the present embodiment, VC++ language secondary development residual stress measurement software XRDWINEDIT is passed through in X-ray residual stress test instrument, it has the parallel interface that can compile, and can control multiple stage residual stress equipment simultaneously.
In the present embodiment, line scanning dough-making powder scan function is added in X-ray residual stress test instrument, as shown in Figure 4, the test point utilizing the X-ray diffraction measuring instrument test zone to measuring material or component enters line scan, centered by weld seam 3, extending on mother metal 2 by test point 4 to both sides, the stress distribution result that line scanning draws is as shown in Figure 5.It is test point 4 scattergram of Surface scan as shown in Figure 6, in test zone, test point uniform spreading is offered and put, test point is carried out Surface scan, and this technology can be in the range of the whole piece continuum set, by setting requirement, automatically residual stress size and distribution are measured, during measurement, can export two dimension cloud atlas and three-dimensional cloud atlas, measurement result is accurate, stress distribution display image is attractive in appearance, clear, can be mutually authenticated with numerical simulation result.
During measuring, using Autofocus Technology, on the basis of aluminum alloy surface horizontal plane, use focusing pin to carry out auto-focusing, focal distance can control at 20mm ± 0.1mm, reduction measurement error as much as possible.
Through CRH2 type bullet train, CRH3 type bullet train entity structure test, calibration technique, Numerical Simulation and comparing with blind hole measuring result, measurement result trend is consistent, numerical value coincide, and measures technically reliable.
Using this Novel high-speed train car body residual stress measurement technology to be applied on the production domesticization high-speed train bodies such as China CRH2, CRH3 and carry out stress measurement, 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 the realization of the present invention, provides basic data to support for China's high-speed train body production, manufacture, has great economic worth and far-reaching social meaning.In this technology, process for treating surface and measurement technology can be applied not only to high-speed train body and can also 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 it has been described above, combine the plan content given by accompanying drawing, similar technical scheme can be derived.In every case it is the content without departing from technical solution of the present invention, any simple modification, equivalent variations and modification above example made according to the technical spirit of the present invention, all still fall within the range of technical solution of the present invention.
Claims (7)
1. a high-speed train body residual stress measuring method, it is characterised in that comprise the steps:
(1) demarcating X-ray residual stress test equipment, different materials of measuring is found matched optimum measurement technological parameter measuring of pedigree by X-ray diffraction scalp acupuncture in technological parameter system；
(2) selected test zone, the surface of test zone is processed, it is made to meet measurement requirement, surface process specifically includes the surface to test zone and carries out weld reinforcement removal, recycling electrobrightening equipment is carried out polishing to surface, removes additional stress layer, arranges compensating module in measurement system, glossing parameter according to pedigree calculates voluntarily, is modified the measurement error causing Stress Release to cause due to the removal of additional stress layer；
(3) selected test point, utilizes X-ray diffraction method that selected surface is carried out residual stress test, and outputs test result；
Correction in above-mentioned steps (2) is the correction that skew occurs for Bragg angle on depth direction, and correction formula is:
Wherein,2θtrFor Bragg angle, 2 θ after revisingobFor test gained Bragg angle, the z-degree of depth, the image standard diffraction angle of θ-1/2, ψ-inclination angle, μ-correction factor；
The Bragg angle replacing former test gained is carried out Stress calculation by the Bragg angle after being corrected, and finally obtains revised stress value.
High-speed train body residual stress measuring method the most according to claim 1, it is characterized in that: in described step (1), the strong bar such as selection is as tensile sample, at least while use tensile stress Theoretical Calculation, electrical measuring method, X-ray residual stress test equipment that the residual stress of the strong bar such as described is tested and calculated, and then X-ray residual stress test equipment is demarcated.
High-speed train body residual stress measuring method the most according to claim 1, it is characterised in that: when being carried out the surface of test zone, selecting saturated NaCl solution is polishing fluid.
High-speed train body residual stress measuring method the most according to claim 1, it is characterised in that: the surface roughness of described test zone is less than 10 μm.
High-speed train body residual stress measuring method the most according to claim 1, it is characterised in that: in the test process of described step (3), also include on the basis of the horizontal plane of test surfaces, utilize focusing pin automatically to carry out the step focused.
High-speed train body residual stress measuring method the most according to claim 1, it is characterized in that: in the test process of described step (3), test point in test zone is entered line scan or Surface scan, to measure size and the distribution of residual stress.
High-speed train body residual stress measuring method the most according to claim 6, it is characterised in that: in described step (3), after test terminates, output test result and include the two-dimentional cloud atlas of residual stress distribution or three-dimensional cloud atlas.
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