CN103792280B - Magnetic nondestructive testing method for contact damage inversion of ferromagnetic material - Google Patents
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Abstract
本发明属于测量技术领域，具体涉及一种铁磁材料接触损伤反演的磁无损检测方法，利用磁传感器检测铁磁构件表面的漏磁场，获得被测表面的初始漏磁信号，通过同轴电缆存储于智能磁记忆仪中；根据被测表面的漏磁信号，计算得到被测表面的漏磁信号的梯度值；通过接触损伤判据及对损伤区域范围进行反演的方法，本发明的益处在于：对目前能源、石化、交通等领域大量使用的铁磁构件接触损伤程度实现在线检测，检测时不会对铁磁构件进行二次的接触损伤，防止接触损伤造成接触面产生的塑形变形，引起铁磁构件咬合松动或产生裂纹，提高了材料的使用寿命。
The invention belongs to the technical field of measurement, and in particular relates to a magnetic non-destructive detection method for contact damage inversion of ferromagnetic materials, which uses a magnetic sensor to detect the leakage magnetic field on the surface of a ferromagnetic component, obtains an initial magnetic leakage signal on the surface to be tested, and passes a coaxial cable Stored in the intelligent magnetic memory instrument; according to the magnetic flux leakage signal of the measured surface, the gradient value of the magnetic flux leakage signal of the measured surface is calculated; through the contact damage criterion and the method of inverting the range of the damaged area, the benefits of the present invention The purpose is to realize online detection of the contact damage degree of ferromagnetic components widely used in the fields of energy, petrochemical, transportation, etc., without secondary contact damage to ferromagnetic components during detection, and to prevent plastic deformation of the contact surface caused by contact damage , causing ferromagnetic components to loosen or crack, which improves the service life of the material.
Description
技术领域technical field
本发明属于测量技术领域，具体涉及一种铁磁材料接触损伤反演的磁无损检测方法。The invention belongs to the technical field of measurement, and in particular relates to a magnetic nondestructive detection method for contact damage inversion of ferromagnetic materials.
背景技术Background technique
在现代工业生产中，由接触造成的损伤比较常见，这些损伤降低了铁磁结构的强度和抗疲劳性能，对设备的完整性、安全性造成严重的威胁。因此，从结构安全角度来说，必须对材料早期损伤、结构性能退化程度以及剩余寿命进行有效监测和评估。In modern industrial production, damage caused by contact is relatively common, which reduces the strength and fatigue resistance of ferromagnetic structures, and poses a serious threat to the integrity and safety of equipment. Therefore, from the perspective of structural safety, it is necessary to effectively monitor and evaluate the early damage of materials, the degree of structural performance degradation, and the remaining life.
无损检测是指在不损害材料/结构使用性能的前提下，用于检测其特征质量，确定其是否达到特定的工程技术要求，是否还可以继续服役的方法，它是检验产品的质量、保证产品安全、延长产品寿命的必要的可靠技术手段。常见的无损检测方法有：磁粉探伤和漏磁检测、声发射技术、超声导波、涡流检测技术等，在确定构件内部是否出现宏观裂纹时具有很好的效果，但往往无法准确判定构件内部是否出现疲劳微损伤；X射线衍射技术可以对金属结构残余应力进行有效检测，但检测深度非常有限(一般在微米量级)，而且对试件表面质量要求高、检测设备复杂、价格昂贵，很难实现在线大范围检测；超声非线性技术在检测结构损伤度时也同样存在对试件表面质量要求高、信号抗干扰性差、无法完成对复杂构件的内应力和损伤程度进行在线检测等诸多问题。与传统的电磁无损检测方法相比，金属磁记忆法具有检测速度快、无需外部激励源、检测设备小巧且易于携带的优点，特别是对检测应力集中区有较高的灵敏度。Non-destructive testing refers to the method used to test the characteristic quality of the material/structure to determine whether it meets the specific engineering technical requirements and whether it can continue to serve without damaging the performance of the material/structure. It is a method to test the quality of the product and ensure the product It is a necessary and reliable technical means for safety and prolonging product life. Common non-destructive testing methods include: magnetic particle testing and magnetic flux leakage testing, acoustic emission technology, ultrasonic guided wave, eddy current testing technology, etc., which have a good effect in determining whether there are macroscopic cracks inside the component, but it is often impossible to accurately determine whether the component is internal. Fatigue micro-damage occurs; X-ray diffraction technology can effectively detect the residual stress of metal structures, but the detection depth is very limited (generally on the order of microns), and the requirements for the surface quality of the specimen are high, the detection equipment is complicated, and the price is expensive. Realize online large-scale detection; Ultrasonic nonlinear technology also has many problems in the detection of structural damage, such as high requirements on the surface quality of the specimen, poor signal anti-interference, and inability to complete online detection of internal stress and damage of complex components. Compared with the traditional electromagnetic nondestructive testing method, the metal magnetic memory method has the advantages of fast detection speed, no external excitation source, small and portable detection equipment, especially high sensitivity for detecting stress concentration areas.
但是，从检测手段来说，对材料和结构由于微损伤造成的早期性能退化的诊断要比确定宏观裂纹困难得多。事实上，发展简便有效的局部应力集中程度(包括初始预应力和累积工作应力)和材料性能早期退化的评价方法，针对大型工程中关键构件的损伤情况进行现场快速无损检测，进而实现对在役设备的安全性和剩余寿命开展有效评估，一直是实验力学和无损检测领域非常关注的课题。However, in terms of detection methods, the diagnosis of early performance degradation of materials and structures due to micro-damages is much more difficult than the determination of macroscopic cracks. In fact, it is necessary to develop a simple and effective evaluation method for the degree of local stress concentration (including initial prestress and cumulative working stress) and early degradation of material properties, and to conduct on-site rapid non-destructive testing for the damage of key components in large-scale projects, thereby realizing the in-service Effective evaluation of equipment safety and remaining life has always been a topic of great concern in the fields of experimental mechanics and nondestructive testing.
反演理论和技术在无损检测领域起着至关重要的作用，无损检测实际面对的是一反问题，即必须依据已检测到的实验信号，结合物理模型与模拟手段建立智能化的实验分析系统，最终反演结构缺陷特征。关于基于实验的反演识别技术，已有一些学者对此开展相关研究，而且一些相关方法也部分得到应用，如遗传算法、模拟退火法、混沌算法等。但是，到目前为止，使用金属磁记忆技术判断有无缺陷及缺陷的位置还是比较成功的，而确定缺陷大小、形状等问题则困难的多，目前关于金属磁记忆无损检测缺陷反演识别研究还很少见到报道，必须开展相关系统研究。Inversion theory and technology play a vital role in the field of non-destructive testing. What non-destructive testing actually faces is an inverse problem, that is, it is necessary to establish intelligent experimental analysis based on the detected experimental signals, combined with physical models and simulation methods. system, and finally invert the structural defect characteristics. Regarding the inversion recognition technology based on experiments, some scholars have carried out relevant research on it, and some related methods have also been partially applied, such as genetic algorithm, simulated annealing method, chaos algorithm and so on. However, so far, the use of metal magnetic memory technology to determine the presence or absence of defects and the location of defects is relatively successful, but it is much more difficult to determine the size and shape of defects. It is rarely reported, and relevant systematic research must be carried out.
对铁磁构件进行检测时会对铁磁构件造成接触损伤，接触损伤可能造成接触表面产生塑性变形，引起铁磁构件咬合处松动，或加速材料疲劳裂纹的萌生和扩展，降低材料的使用寿命。When testing ferromagnetic components, it will cause contact damage to ferromagnetic components. Contact damage may cause plastic deformation of the contact surface, causing loosening of ferromagnetic component joints, or accelerating the initiation and expansion of material fatigue cracks, reducing the service life of materials.
发明内容Contents of the invention
本发明所要解决的技术问题是针对现有技术的不足，提供一种铁磁材料接触损伤反演的磁无损检测方法。The technical problem to be solved by the present invention is to provide a magnetic non-destructive testing method for contact damage inversion of ferromagnetic materials in view of the deficiencies in the prior art.
为了实现上述发明目的，本发明提出了一种铁磁材料接触损伤反演的磁无损检测方法，包括以下步骤：In order to achieve the purpose of the above invention, the present invention proposes a magnetic nondestructive testing method for contact damage inversion of ferromagnetic materials, including the following steps:
步骤1）铁磁构件初始漏磁信号的测定：通过同轴电缆将磁传感器与智能磁记忆仪连接，利用磁传感器在同一平面沿互相垂直的两个方向检测铁磁试件的表面，获得被测表面的初始漏磁信号，并存储于智能磁记忆仪中；Step 1) Determination of the initial magnetic flux leakage signal of ferromagnetic components: Connect the magnetic sensor with the intelligent magnetic memory instrument through a coaxial cable, use the magnetic sensor to detect the surface of the ferromagnetic test piece in two directions perpendicular to each other on the same plane, and obtain the measured The initial magnetic flux leakage signal of the measured surface is stored in the intelligent magnetic memory device;
步骤2）接触后铁磁构件漏磁信号的测定：对铁磁构件进行接触加载，利用铁磁压头对铁磁构件进行加载，到一定载荷后进行卸载，将铁磁构件取下并进行漏磁检测，测得铁磁构件受压面的漏磁信号；Step 2) Measurement of the magnetic flux leakage signal of the ferromagnetic component after contact: Carry out contact loading on the ferromagnetic component, use the ferromagnetic indenter to load the ferromagnetic component, unload it after reaching a certain load, remove the ferromagnetic component and perform leakage Magnetic detection, measuring the magnetic flux leakage signal of the pressure surface of the ferromagnetic component;
步骤3）梯度值的计算：将步骤2）中测得的漏磁信号减去步骤1）中测得的初始漏磁信号，消除初始其他因素的干扰，根据得到的被测表面的漏磁信号，计算得到被测表面的漏磁信号的梯度值；Step 3) Calculation of the gradient value: Subtract the initial magnetic flux leakage signal measured in step 1) from the magnetic flux leakage signal measured in step 2) to eliminate the interference of other initial factors. According to the obtained magnetic flux leakage signal of the measured surface , to calculate the gradient value of the magnetic flux leakage signal on the measured surface;
步骤4）接触损伤区的反演：通过接触损伤的评价判据和评价参数对接触损伤区范围进行反演。Step 4) Inversion of the contact damage area: Invert the range of the contact damage area through the evaluation criteria and evaluation parameters of the contact damage.
所述步骤3）还包括：无法获得铁磁构件的初始漏磁信号，则省略消除初始因素干扰这一步骤，直接计算被测表面的漏磁信号的梯度值；The step 3) also includes: if the initial magnetic flux leakage signal of the ferromagnetic component cannot be obtained, the step of eliminating the interference of the initial factor is omitted, and the gradient value of the magnetic flux leakage signal on the measured surface is directly calculated;
初始漏磁信号包括法向初始漏磁信号和切向初始漏磁信号；漏磁信号包括法向漏磁信号和切向漏磁信号；梯度值包括法向漏磁信号的梯度值和切向漏磁信号的梯度值；The initial magnetic flux leakage signal includes the normal initial magnetic flux leakage signal and tangential initial flux leakage signal ;The magnetic flux leakage signal includes the normal magnetic flux leakage signal and tangential flux leakage signal ;The gradient value includes the gradient value of the normal magnetic flux leakage signal and the gradient value of the tangential flux leakage signal ;
定义法向漏磁信号的梯度值： Define the gradient value of the normal flux leakage signal:
定义切向漏磁信号的梯度值： Define the gradient value of the tangential flux leakage signal:
接触损伤的评价判据，在接触应力集中区，法向漏磁信号出现一个极值，漏磁梯度出现峰－峰值变化，并在接触区中心位置过零点；切向漏磁信号出现峰－峰值变化并且过零点，漏磁梯度出现极值。The evaluation criterion of contact damage is that in the contact stress concentration area, the normal magnetic flux leakage signal has an extreme value, the magnetic flux leakage gradient has a peak-to-peak change, and crosses zero at the center of the contact area; the tangential magnetic flux leakage signal has a peak-to-peak value changes and crosses zero, the magnetic flux leakage gradient presents an extremum.
利用法向漏磁信号的梯度峰－峰值的作用宽度和切向漏磁信号的梯度幅值的作用宽度这两个参数均可以反映接触损伤区的范围。在实际测量中，需要沿同一测试方向(x方向)进行多路径测量，得到不同路径上这两个参数，捕捉每条路径上反映的损伤区宽度；再沿垂直方向(y方向)进行多路径测量，得到不同路径上这两个参数，捕捉每条路径上反映的损伤区宽度，两个方向上这些宽度间形成的区域基本反演了损伤区的形状。其中法向漏磁信号的梯度峰－峰值对损伤区形状更为敏感。The range of the contact damage zone can be reflected by the two parameters of the gradient peak-to-peak action width of the normal magnetic flux leakage signal and the gradient amplitude action width of the tangential magnetic flux leakage signal. In the actual measurement, it is necessary to carry out multi-path measurement along the same test direction (x direction), obtain these two parameters on different paths, and capture the width of the damaged area reflected on each path; then carry out multi-path along the vertical direction (y direction) Measure to obtain these two parameters on different paths, capture the width of the damaged area reflected on each path, and the area formed between these widths in two directions basically inverts the shape of the damaged area. The peak-to-peak gradient of the normal magnetic flux leakage signal is more sensitive to the shape of the damage zone.
将实际检测得到的法向漏磁信号的梯度峰－峰值的作用宽度，以及切向漏磁信号的梯度幅值的作用宽度与其临界安全值进行比较，如实际测量值小于临界安全值则构件安全，反之则为不安全。其中临界安全值是根据不同材料和不同损伤安全等级，在正式检测之前用标准试块标定得到的评价构件损伤程度的参数。Compare the action width of the gradient peak-to-peak value of the normal magnetic flux leakage signal obtained by actual detection, and the action width of the gradient amplitude of the tangential magnetic flux leakage signal with their critical safety values. If the actual measured value is less than the critical safety value, the component is safe. , otherwise it is unsafe. Among them, the critical safety value is a parameter to evaluate the damage degree of the component obtained by calibrating the standard test block before the formal inspection according to different materials and different damage safety levels.
本发明的益处在于：对目前能源、石化、交通等领域大量使用的铁磁构件接触损伤程度实现在线检测，检测时不会对铁磁构件进行二次的接触损伤，防止接触损伤造成接触面产生的塑形变形，引起铁磁构件咬合松动或产生裂纹，提高了材料的使用寿命。The benefit of the present invention is that it realizes on-line detection of the degree of contact damage of ferromagnetic components widely used in the fields of energy, petrochemical, transportation, etc., and does not cause secondary contact damage to ferromagnetic components during detection, preventing contact damage from causing contact surface damage The plastic deformation of the ferromagnetic components causes loosening or cracks in the ferromagnetic components, which improves the service life of the material.
附图说明Description of drawings
图1为铁磁材料接触损伤的磁无损检测方法流程图；Fig. 1 is a flow chart of a magnetic nondestructive testing method for contact damage to ferromagnetic materials;
图2为铁磁材料接触损伤的磁无损检测系统示意图；Figure 2 is a schematic diagram of a magnetic nondestructive testing system for contact damage to ferromagnetic materials;
图3为铁磁构件接触损伤区法向漏磁信号结果示意图；Figure 3 is a schematic diagram of the results of the normal magnetic flux leakage signal in the contact damage area of the ferromagnetic component;
图4为铁磁构件接触损伤区切向漏磁信号结果示意图；Fig. 4 is a schematic diagram of the results of the tangential magnetic flux leakage signal in the contact damage area of the ferromagnetic component;
图5为铁磁构件接触损伤区法向漏磁信号梯度值结果示意图；Fig. 5 is a schematic diagram of the result of the gradient value of the normal magnetic flux leakage signal in the contact damage area of the ferromagnetic component;
图6为铁磁构件接触损伤区切向漏磁信号梯度值结果示意图；Fig. 6 is a schematic diagram of the results of the gradient value of the tangential magnetic flux leakage signal in the contact damage area of the ferromagnetic component;
图7为实施例中的加载方式立体示意图；Fig. 7 is the three-dimensional schematic diagram of the loading mode in the embodiment;
图8为实施例中的加载方式侧面示意图；Fig. 8 is a schematic side view of the loading mode in the embodiment;
图9为测量沿x方向的迹线分布示意图；Fig. 9 is a schematic diagram of measuring trace distribution along the x direction;
图10为测量沿y方向的迹线分布示意图；Fig. 10 is a schematic diagram of measuring trace distribution along the y direction;
图11为测量沿x方向迹线上的测点布置图；Fig. 11 is a diagram of measuring point layout along the x-direction trace;
图12为测量沿y方向迹线上的测点布置图；Fig. 12 is a measurement point layout diagram along the y-direction trace;
图13为沿y方向不同迹线下的法向漏磁信号分布图，当F=80kN时；Figure 13 is the distribution diagram of the normal magnetic flux leakage signal under different traces along the y direction, when F=80kN;
图14为沿y方向不同迹线下的法向漏磁信号分布图，当F=80kN时；Figure 14 is the distribution diagram of the normal magnetic flux leakage signal under different traces along the y direction, when F=80kN;
图15为沿x方向不同迹线下的法向漏磁信号分布图；Fig. 15 is the normal magnetic flux leakage signal distribution diagram under different traces along the x direction;
图16为沿x方向不同迹线下的法向漏磁信号分布图；Fig. 16 is the normal magnetic flux leakage signal distribution diagram under different traces along the x direction;
图17为沿y方向不同迹线下的法向漏磁信号的梯度值分布图；Figure 17 is a distribution diagram of the gradient value of the normal magnetic flux leakage signal under different traces along the y direction;
图18为沿y方向不同迹线下的法向漏磁信号的梯度值分布图；Fig. 18 is a distribution diagram of the gradient value of the normal magnetic flux leakage signal under different traces along the y direction;
图19为沿x方向不同迹线下的法向漏磁信号的梯度值分布图；Fig. 19 is a distribution diagram of the gradient value of the normal magnetic flux leakage signal under different traces along the x direction;
图20为沿x方向不同迹线下的法向漏磁信号的梯度值分布图；Fig. 20 is a distribution diagram of the gradient value of the normal magnetic flux leakage signal under different traces along the x direction;
图21为x方向测量漏磁场突变点坐标图；Fig. 21 is a coordinate diagram of the sudden change point of the leakage magnetic field measured in the x direction;
图22为y方向测量漏磁场突变点坐标图；Fig. 22 is a coordinate diagram of the sudden change point of the leakage magnetic field measured in the y direction;
图23为80kN下损伤区域反演坐标图。Fig. 23 is an inversion coordinate map of the damaged area under 80kN.
具体实施方式detailed description
当结合附图考虑时，通过参照下面的详细描述，能够更完整更好地理解本发明以及容易得知其中许多伴随的优点，但此处所说明的附图用来提供对本发明的进一步理解，构成本发明的一部分。A more complete and better understanding of the invention, and many of its attendant advantages, will readily be learned by reference to the following detailed description when considered in conjunction with the accompanying drawings, but the accompanying drawings illustrated herein are intended to provide a further understanding of the invention and constitute part of the invention.
为使本发明的上述目的、特征和优点能够更加明显易懂，下面以45号钢铁磁构件的检测的法向漏磁信号为例，结合附图和具体实施方式对本发明作进一步详细的说明。In order to make the above-mentioned purpose, features and advantages of the present invention more obvious and easy to understand, the present invention will be further described in detail below with reference to the accompanying drawings and specific implementation methods by taking the detected normal magnetic flux leakage signal of No. 45 steel magnetic component as an example.
实施例1：如图1至图23所示，Embodiment 1: As shown in Figure 1 to Figure 23,
步骤1）如图7和图8所示，利用圆柱形铁磁压头对铁磁构件进行加载，加载至80kN后进行卸载，将铁磁构件取下并进行漏磁检测，如图7至图10所示，沿不同路径和迹点利用笔试磁传感器点测铁磁构件受压面表面，如图13至图16所示，分别测得沿y方向和沿x方向不同迹线下的法向漏磁信号并存储于智能磁记忆仪中；Step 1) As shown in Figure 7 and Figure 8, use a cylindrical ferromagnetic indenter to load the ferromagnetic component, unload it after loading to 80kN, remove the ferromagnetic component and perform a magnetic flux leakage test, as shown in Figure 7 to Figure As shown in Figure 10, the surface of the pressure surface of the ferromagnetic component is measured with a pen test magnetic sensor along different paths and trace points. MFL signal And stored in the intelligent magnetic memory device;
步骤2）对铁磁构件进行接触加载，利用铁磁压头对铁磁构件进行加载，到一定载荷后进行卸载，将铁磁构件取下并进行漏磁检测，测得铁磁构件受压面的法向漏磁信号 Step 2) Carry out contact loading on the ferromagnetic component, use the ferromagnetic indenter to load the ferromagnetic component, unload it after reaching a certain load, remove the ferromagnetic component and perform magnetic flux leakage detection, and measure the pressure surface of the ferromagnetic component The normal magnetic flux leakage signal
步骤3）将接触后测得的漏磁信号减去初始漏磁信号，可以消除初始其他因素的干扰，如图17至图20所示，计算被测表面沿y方向和沿x方向不同迹线下的法向漏磁信号的梯度值 Step 3) Subtract the initial magnetic flux leakage signal from the measured magnetic flux leakage signal after contact, which can eliminate the interference of other initial factors, as shown in Figure 17 to Figure 20, and calculate the different traces of the measured surface along the y direction and along the x direction The gradient value of the normal magnetic flux leakage signal under
定义法向漏磁信号的梯度值： Define the gradient value of the normal flux leakage signal:
步骤4）在接触损伤判据的基础上，利用法向漏磁信号梯度的峰－峰值的作用宽度这个参数对接触损伤区的范围进行反演，确定接触损伤区的范围：在x测量方向，获得每条路径上的漏磁信号梯度曲线的评价参数中的两个坐标点并分别绘于图21；在y测量方向进行同样的处理，并将捕捉到的坐标点一并绘入图22中，两个方向上这些坐标点间所形成的区域基本反演了接触损伤区的形状，由此可见，这种接触损伤检测评价与反演的磁无损检测方法是可行、可靠的，并且比较准确。Step 4) On the basis of the contact damage criterion, use the peak-to-peak action width of the normal magnetic flux leakage signal gradient This parameter inverts the range of the contact damage zone to determine the range of the contact damage zone: in the x measurement direction, the evaluation parameters of the gradient curve of the magnetic flux leakage signal on each path are obtained middle The two coordinate points are drawn separately in Figure 21; the same process is carried out in the y measurement direction, and the captured coordinate points are drawn together in Figure 22, and the area formed between these coordinate points in the two directions is basically inverted The shape of the contact damage area is obtained, so it can be seen that the magnetic non-destructive testing method of contact damage detection evaluation and inversion is feasible, reliable and relatively accurate.
步骤5）对45号钢标准块进行加载，同时测量其漏磁信号，得到标准块接触损伤程度和漏磁信号之间的对应关系，根据实际被测45号钢构件的工作安全等级，确定法向漏磁信号的梯度峰－峰值和作用宽度以及切向漏磁信号的梯度幅值和作用宽度的临界安全值；Step 5) Load the No. 45 steel standard block and measure its magnetic flux leakage signal at the same time to obtain the corresponding relationship between the contact damage degree of the standard block and the magnetic flux leakage signal. Gradient peak-to-peak value of magnetic flux leakage signal and action width and the gradient amplitude of the tangential magnetic flux leakage signal and action width critical safety value;
步骤6）将实际检测得到的法向漏磁信号的梯度峰－峰值的作用宽度以及切向漏磁信号的梯度幅值的作用宽度与临界安全值进行比较，如实际测量值小于临界安全值则构件安全，反之则为不安全。Step 6) The gradient peak-to-peak action width of the actual detected normal magnetic flux leakage signal And the action width of the gradient amplitude of the tangential magnetic flux leakage signal Compared with the critical safety value, if the actual measured value is less than the critical safety value, the component is safe, otherwise it is unsafe.
以上对本发明所提供的一种铁磁材料接触损伤反演的磁无损检测方法进行了详细介绍，以上参照附图对本申请的示例性的实施方案进行了描述。本领域技术人员应该理解，上述实施方案仅仅是为了说明的目的而所举的示例，而不是用来进行限制，凡在本申请的教导和权利要求保护范围下所作的任何修改、等同替换等，均应包含在本申请要求保护的范围内。A magnetic non-destructive testing method for contact damage inversion of ferromagnetic materials provided by the present invention has been introduced in detail above, and an exemplary embodiment of the present application has been described above with reference to the accompanying drawings. It should be understood by those skilled in the art that the above-mentioned embodiments are only examples for the purpose of illustration, and are not used for limitation. Any modifications, equivalent replacements, etc. All should be included in the protection scope of this application.
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