CN110749391A - Cutter residual stress testing system and method based on magnetoacoustic emission principle - Google Patents
Cutter residual stress testing system and method based on magnetoacoustic emission principle Download PDFInfo
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- CN110749391A CN110749391A CN201911067369.3A CN201911067369A CN110749391A CN 110749391 A CN110749391 A CN 110749391A CN 201911067369 A CN201911067369 A CN 201911067369A CN 110749391 A CN110749391 A CN 110749391A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L5/00—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes
- G01L5/0047—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes measuring forces due to residual stresses
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L1/00—Measuring force or stress, in general
- G01L1/12—Measuring force or stress, in general by measuring variations in the magnetic properties of materials resulting from the application of stress
Abstract
The invention discloses a cutter residual stress testing system and method based on a magnetoacoustic emission principle, wherein the system comprises: the device comprises a pulse power supply, an exciting coil, a test sensor, a fixture and a processor, wherein the pulse power supply is connected with the exciting coil and provides current with preset magnitude for the exciting coil; the test sensor and the tool to be tested are arranged in the exciting coil, the clamp is used for attaching the test sensor to the upper surface of the tool to be tested, the exciting coil provides an alternating magnetic field for the tool to be tested, and the test sensor is used for collecting stress waves generated after the tool to be tested is influenced by the magnetic field; the processor is connected with the test sensor and used for receiving and processing the stress wave and outputting the residual stress level of the tool to be tested. The system has the advantages of more convenient detection means, lower cost, capability of evaluating the integral residual stress level and greatly improved timeliness under the condition of good accuracy.
Description
Technical Field
The invention relates to the technical field of residual stress detection, in particular to a cutter residual stress testing system and method based on a magnetoacoustic emission principle.
Background
With the rapid development of the industry, the demand for high-quality tools is increasing day by day. The cutter can produce residual stress of different degrees after being processed and delivered from the factory and used, and the level of the residual stress directly influences the quality of the cutter and the service life of the cutter. The existing cutter mostly uses high-speed steel and hard alloy materials as a substrate, the surface of the cutter is coated with a hardened coating, the hardness is very high, and the traditional destructive residual stress measurement means is difficult to work.
The existing residual stress detection means are divided into two categories, namely destructive detection and nondestructive detection. In the aspect of destructive detection, a ring core method, a blind hole method and the like are generally adopted, and in the aspect of nondestructive detection, X-ray detection, neutron diffraction and the like are commonly used. The two methods have different degrees of defects in operation difficulty, cost and efficiency.
In destructive detection such as a blind hole method, a blind hole with a certain depth and diameter needs to be drilled on the surface to be detected, the magnitude of residual stress is reversely deduced through strain change recorded by a strain rosette, and great defects exist in operation space and operation efficiency. And the performance evaluation can be carried out only by adopting a sampling method in response to the large-batch detection of the small-sized cutters. Meanwhile, the detected cutter can not be used any more, and the destructive detection is impossible in the aspect of dynamic evaluation. In the aspect of common nondestructive residual stress detection, such as an X-ray diffractometer, the operation is complicated, the evaluation area is too small, the cost is too high, the industrial application is not facilitated, and the mass test cannot be performed.
The existing application of detecting the residual stress by using the magnetoacoustic emission principle is not common, and in domestic and foreign researches, the residual stress of large-scale components such as welding containers, train wheels, war chariot, missiles and the like after heat treatment is detected, but the residual stress of cutters is not detected by using a magnetoacoustic emission method.
Disclosure of Invention
The present invention is directed to solving, at least to some extent, one of the technical problems in the related art.
Therefore, the invention aims to provide a tool residual stress testing system based on the magnetoacoustic emission principle.
The invention also aims to provide a cutter residual stress testing method based on the magnetoacoustic emission principle, which has extremely high efficiency and good accuracy, does not damage a sample, and is simple and convenient to operate and very economical.
In order to achieve the above object, an embodiment of the invention provides a tool residual stress testing system based on a magnetoacoustic emission principle, which includes a pulse power supply, an excitation coil, a test sensor, a fixture and a processor, wherein the pulse power supply is connected to the excitation coil and provides a current with a preset magnitude for the excitation coil; the test sensor and the tool to be tested are arranged in the exciting coil, the clamp is used for attaching the test sensor to the upper surface of the tool to be tested, the exciting coil provides an alternating magnetic field for the tool to be tested, and the test sensor is used for collecting stress waves generated after the tool to be tested is influenced by the magnetic field; the processor is connected with the test sensor and used for receiving and processing the stress wave and outputting the residual stress level of the tool to be tested.
The cutter residual stress testing system based on the magnetoacoustic emission principle has the advantages of simple system structure, low cost, simplicity and convenience in operation, greatly improves timeliness under the condition of evaluating the integral residual stress level and good accuracy, has extremely high efficiency and good accuracy, and does not damage a sample.
In addition, the tool residual stress testing system based on the magnetoacoustic emission principle according to the above embodiment of the present invention may further have the following additional technical features:
further, in one embodiment of the present invention, the clip comprises: the two turntables are arranged on two sides of the cutter to be tested and used for clamping the fixed cutter to be tested, and the spiral pressure head is used for attaching the sensor to the upper surface of the cutter to be tested.
Further, in one embodiment of the present invention, a contact surface of the test sensor and the tool to be tested is coated with a couplant.
Further, in an embodiment of the present invention, the method further includes: the lead is used for connecting the pulse power supply with the exciting coil; the signal amplifier is respectively connected with the test sensor and the processor and is used for amplifying the stress wave; a signal transmission data line for transmitting the stress wave to the processor.
Further, in an embodiment of the present invention, the test sensor is configured to collect a stress wave generated after the tool to be tested is affected by a magnetic field, and specifically includes: under the action of the alternating magnetic field, the crystal lattice of the cutter to be tested generates a magnetostriction phenomenon, relative displacement is generated in the two magnetic domains, the stress wave is caused by the relative displacement and released, and the stress wave is collected by the test sensor.
In order to achieve the above object, another embodiment of the present invention provides a method for testing residual stress of a tool based on a magnetoacoustic emission principle, including the following steps: inputting a preset current to the exciting coil to enable the cutter to be detected to be placed in a preset alternating magnetic field; collecting stress waves generated by the cutter to be tested under the influence of a magnetic field by using a test sensor; and transmitting the stress wave to a processor for processing, and outputting the residual stress level of the tool to be tested.
The cutter residual stress testing method based on the magnetoacoustic emission principle is simple and convenient to operate and very economical, the overall residual stress level is evaluated, the timeliness is greatly improved under the condition of good accuracy, the efficiency is high, the accuracy is good, and meanwhile a sample is not damaged.
In addition, the tool residual stress testing method based on the magnetoacoustic emission principle according to the above embodiment of the present invention may further have the following additional technical features:
further, in an embodiment of the present invention, the acquiring, by using a test sensor, a stress wave generated by the tool to be tested under the influence of a magnetic field includes: under the action of the alternating magnetic field, the crystal lattice of the cutter to be tested generates a magnetostriction phenomenon, relative displacement is generated in the two magnetic domains, the relative displacement causes the stress wave, and the stress wave is released; and the test sensor detects the signal change of the cutter to be tested and collects the stress wave, wherein the test sensor is attached to the upper surface of the cutter to be tested by using a clamp.
Further, in an embodiment of the present invention, the transmitting the stress wave to a processor for processing and outputting the residual stress level of the tool to be tested includes: transmitting the stress wave into the processor, and expressing the stress wave by using the inelastic strain tensor of the volume infinitesimal of the magnetic domain area of the cutter to be measured; and processing the inelastic strain tensor to obtain MAE signal intensity, and evaluating the residual stress level of the tool to be measured according to the MAE signal intensity.
Further, in one embodiment of the present invention, the inelastic strain tensor is related to the MAE signal strength by the formula:
wherein, VpAnd C is residual stress, C is a material parameter of the cutter to be measured, DeltaV is a volume infinitesimal element of the cutter to be measured in the magnetic domain region, Deltaepsilon is inelastic strain tensor, and tau is the time for increasing Deltaepsilon.
Further, in an embodiment of the present invention, the strength of the MAE signal is in tensor direct relation with the inelastic strain, and the strength of the MAE signal is in direct relation with the residual stress level of the tool to be measured.
Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
Drawings
The foregoing and/or additional aspects and advantages of the present invention will become apparent and readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1 is a schematic structural diagram of a system for testing residual stress of a tool according to an embodiment of the present invention;
FIG. 2 is a schematic view of a chuck according to one embodiment of the present invention;
FIG. 3 is a diagram of ring count rate versus excitation time in accordance with an illustrative example of the present invention;
FIG. 4 is a graph of unit mean amplitude versus excitation time in accordance with a specific example of the present invention;
fig. 5 is a flowchart of a method for testing residual stress of a tool based on a magnetoacoustic emission principle according to an embodiment of the present invention.
Description of reference numerals: 10-a cutter residual stress testing system based on a magnetoacoustic emission principle, 100-a pulse power supply, 200-an exciting coil, 300-a testing sensor, 400-a fixture, 500-a processor, 600-a lead, 700-a signal amplifier and 800-a signal transmission data line.
Detailed Description
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the drawings are illustrative and intended to be illustrative of the invention and are not to be construed as limiting the invention.
Hereinafter, a tool residual stress testing system and method based on the magnetoacoustic emission principle according to an embodiment of the present invention will be described with reference to the accompanying drawings.
FIG. 1 is a schematic structural diagram of a system for testing residual stress of a tool based on magnetoacoustic emission principle according to an embodiment of the present invention.
As shown in fig. 1, the system 10 includes: a pulsed power supply 100, an excitation coil 200, a test sensor 300, a fixture 400, and a processor 500.
The pulse power supply 100 is connected with the exciting coil 200, and the pulse power supply 100 provides current with a preset magnitude for the exciting coil 200; the test sensor 300 and the tool to be tested are arranged in the exciting coil 200, the clamp 400 is used for attaching the test sensor 300 to the upper surface of the tool to be tested, the exciting coil 200 provides an alternating magnetic field for the tool to be tested, and the test sensor 300 is used for collecting stress waves generated after the tool to be tested is influenced by the magnetic field; the processor 500 is connected with the test sensor 300, and the processor 500 is used for receiving and processing the stress wave and outputting the residual stress level of the tool to be tested. The cutter residual stress testing system provided by the embodiment of the invention has a simple structure, is easy to operate, evaluates the integral residual stress level, and greatly improves the timeliness under the condition of good accuracy.
Further, the embodiment of the present invention further includes: a conductor 600, a signal amplifier 700 and a signal transmission data line 800. The lead 600 is used for connecting the pulse power supply 100 and the exciting coil 200; the signal amplifier 700 is respectively connected with the test sensor 300 and the processor 500 and is used for amplifying stress waves; a signal transmission data line 800 for transmitting the stress wave to the processor 500.
It should be noted that, in the embodiment of the present invention, the number of turns of the pulse coil may be set to 100 turns of copper wire winding, and the maximum current that can pass through the copper wire is 100A; the acoustic emission system adopts a PCI-2 signal acquisition card, an 2/4/6 signal amplifier and a nano30 sensor provided by PAC company, and signal processing software is AEwin; the power supply is a comprehensive power supply with adjustable frequency, adjustable current and adjustable output current mode, the frequency range is 1-50 Hz, the current range is 0-10A, and the mode can be selected from square waves, triangular waves, sine waves and the like. It should be noted that, those skilled in the art can select the device type and parameters according to actual situations, and the device type and parameters are not specifically limited herein.
Further, the test sensor and the tool to be tested need to be fixed by means of a fixture, as shown in fig. 2, the tool to be tested is clamped and fixed by the turntable of the fixture on two sides, the acoustic emission sensor is attached to the upper surface of the test tool, and a coupling agent is coated on the contact part of the surface. The acoustic emission sensor and the cutter to be tested need to be fixed through a spiral pressure head of the fixture, and the stability of signal transmission during testing is guaranteed.
Further, in an embodiment of the present invention, the test sensor 300 is used for collecting a stress wave generated after the tool to be tested is affected by a magnetic field, and specifically includes: under the action of the alternating magnetic field, the lattice of the tool to be tested generates a magnetostriction phenomenon, relative displacement is generated in the two magnetic domains, stress waves are caused by the relative displacement, the stress waves are released, and the test sensor 300 collects the stress waves.
Specifically, the tool to be measured can be made of a ferromagnetic material or a paramagnetic material, and the tool to be measured generates a magnetostrictive phenomenon under the action of a variable alternating magnetic field, that is, the length and the volume of the tool to be measured can be changed due to the elastic deformation of crystal lattices. When magnetization is carried out, the magnetic domain wall in the magnetic core can suddenly move and the magnetization vector rotates, magnetostriction in the two magnetic domains is inconsistent, relative displacement occurs, stress waves are caused by the relative displacement and released, and the test sensor attached to the surface of the tool to be tested senses signals to collect the stress waves.
In summary, the working principle of the embodiment of the invention is as follows: the pulse power supply 100 transmits current to the exciting coil 200 through a lead 600, the energized exciting coil 200 generates an alternating magnetic field, a magnetic domain wall inside a tool to be tested, which is positioned inside the exciting coil 200 and is influenced by the magnetic field, relatively displaces to generate and release stress waves, the test sensor 300 attached to the surface of the tool to be tested senses signals, the stress waves are collected and transmitted to the signal amplifier 700 through a signal transmission data line 800 or directly transmitted to the processor 500, after the processor receives the stress waves, the stress waves are expressed by using inelastic strain tensor of volume infinitesimal of a magnetic domain area of the tool to be tested, the inelastic strain tensor is processed to obtain the strength of an MAE signal, the residual stress level of the tool to be tested is evaluated according to the strength of the MAE signal, and the residual stress level of the.
The relation formula of the inelastic strain tensor and the MAE signal intensity is as follows:
in the formula, VpIs residual stress, and C is material parameter of the tool to be measuredAnd the number is delta V, delta epsilon and tau, wherein delta V is the volume infinitesimal of the cutter to be measured in the magnetic domain area, delta epsilon is the inelastic strain tensor, and tau is the time for increasing delta epsilon.
According to the above formula, the strength of the MAE signal is proportional to the inelastic strain inside the magnetic domain, and therefore the strength of the MAE signal is proportional to the residual stress level inside the material, and the residual stress level inside the material can be evaluated by observing the strength of the MAE signal.
And analyzing the residual stress level and the distribution condition in the tool to be tested by evaluating the ringing count rate, the amplitude and the peak frequency of the received signal.
To examine the effect, 2 test pieces of 45 steel (phi 20, h 10) of the same size were sampled and subjected to annealing and quenching, respectively. Then, magnetic acoustic emission inspection under magnetic excitation is carried out, and parameters such as ringing counting rate, signal amplitude and the like can be evaluated, so that the residual stress level can be estimated. The ring count rate is counted as the number of signal rings in a unit time, and the unit mean amplitude of the signal is the average of the amplitudes of all impact signals in the unit time.
As shown in fig. 3 and 4, the acoustic emission signal amplitude and ringing of the quenched 45 steel with high residual stress levels are at high levels, while the acoustic emission signal amplitude and ringing levels of the annealed 45 steel are low. According to this method, when testing the residual stress level of the tool, the residual stress level of the processed tool can be evaluated as long as the same tool in an annealed state is used as a comparison group.
The cutter residual stress testing system based on the magnetoacoustic emission principle, provided by the embodiment of the invention, has the advantages of simple system structure, low cost, simplicity and convenience in operation, greatly improved timeliness under the condition of evaluating the integral residual stress level and good accuracy, extremely high efficiency and good accuracy, and simultaneously does not damage a sample.
Next, a flow chart of a tool residual stress testing method based on the magnetoacoustic emission principle according to an embodiment of the present invention is described with reference to the drawings.
As shown in fig. 5, the method for testing residual stress of a tool based on the magnetoacoustic emission principle, which uses the tool residual stress system, includes the following steps:
in step S501, a current with a preset magnitude is input to the exciting coil, so that the tool to be measured is placed in a variable alternating magnetic field with a preset magnitude.
In step S502, a stress wave generated by the tool to be tested under the influence of the magnetic field is collected by the test sensor.
Further, in an embodiment of the present invention, the acquiring, by using a test sensor, a stress wave generated by the tool to be tested under the influence of a magnetic field includes:
under the action of the alternating magnetic field, the crystal lattice of the cutter to be tested generates a magnetostriction phenomenon, relative displacement is generated in the two magnetic domains, stress waves are caused by the relative displacement, and the stress waves are released;
the test sensor detects the signal change of the cutter to be tested and collects stress waves, wherein the test sensor is attached to the upper surface of the cutter to be tested by the fixture.
In step S503, the stress wave is transmitted to the processor for processing, and the residual stress level of the tool to be measured is output.
Further, in an embodiment of the present invention, transmitting the stress wave to a processor for processing, and outputting the residual stress level of the tool to be tested, includes: transmitting the stress wave to a processor, and expressing the stress wave by using the inelastic strain tensor of the volume infinitesimal of the magnetic domain area of the cutter to be measured; and processing the inelastic strain tensor to obtain the MAE signal intensity, and evaluating the residual stress level of the tool to be measured according to the MAE signal intensity.
Further, in one embodiment of the present invention, the inelastic strain tensor is related to the MAE signal strength by the formula:
wherein, VpAnd C is residual stress, C is a material parameter of the cutter to be measured, DeltaV is a volume infinitesimal element of the cutter to be measured in the magnetic domain region, Deltaepsilon is inelastic strain tensor, and tau is the time for increasing Deltaepsilon.
Further, in an embodiment of the present invention, the strength of the MAE signal is in tensor direct relation with the inelastic strain, and the strength of the MAE signal is in direct relation with the residual stress level of the tool to be measured.
The cutter residual stress testing method based on the magnetoacoustic emission principle is simple and convenient to operate and very economical, the overall residual stress level is evaluated, the timeliness is greatly improved under the condition of good accuracy, the efficiency is high, the accuracy is good, and meanwhile a sample is not damaged.
Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "a plurality" means at least two, e.g., two, three, etc., unless specifically limited otherwise.
In the description herein, references to the description of the term "one embodiment," "some embodiments," "an example," "a specific example," or "some examples," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, various embodiments or examples and features of different embodiments or examples described in this specification can be combined and combined by one skilled in the art without contradiction.
Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention, and that variations, modifications, substitutions and alterations can be made to the above embodiments by those of ordinary skill in the art within the scope of the present invention.
Claims (10)
1. A cutter residual stress test system based on a magnetoacoustic emission principle is characterized by comprising: a pulse power supply, an excitation coil, a test sensor, a fixture, and a processor, wherein,
the pulse power supply is connected with the exciting coil and provides current with a preset magnitude for the exciting coil;
the test sensor and the tool to be tested are arranged in the exciting coil, the clamp is used for attaching the test sensor to the upper surface of the tool to be tested, the exciting coil provides an alternating magnetic field for the tool to be tested, and the test sensor is used for collecting stress waves generated after the tool to be tested is influenced by the magnetic field;
the processor is connected with the test sensor and used for receiving and processing the stress wave and outputting the residual stress level of the tool to be tested.
2. The system for testing residual stress of a cutter based on the magnetoacoustic emission principle of claim 1, wherein the fixture comprises: the two turntables are arranged on two sides of the cutter to be tested and used for clamping the fixed cutter to be tested, and the spiral pressure head is used for attaching the sensor to the upper surface of the cutter to be tested.
3. The system for testing the residual stress of the cutter based on the magnetoacoustic emission principle as claimed in claim 1, wherein a contact surface of the test sensor and the cutter to be tested is coated with a coupling agent.
4. The system for testing residual stress of a cutter based on the magnetoacoustic emission principle of claim 1, further comprising:
the lead is used for connecting the pulse power supply with the exciting coil;
the signal amplifier is respectively connected with the test sensor and the processor and is used for amplifying the stress wave;
a signal transmission data line for transmitting the stress wave to the processor.
5. The cutter residual stress test system based on the magnetoacoustic emission principle as claimed in claim 1, wherein the test sensor is configured to collect a stress wave generated after the cutter to be tested is affected by a magnetic field, and specifically includes:
under the action of the alternating magnetic field, the crystal lattice of the cutter to be tested generates a magnetostriction phenomenon, relative displacement is generated in the two magnetic domains, the stress wave is caused by the relative displacement and released, and the stress wave is collected by the test sensor.
6. A tool residual stress testing method based on the magnetoacoustic emission principle, which adopts the tool residual stress testing system based on the magnetoacoustic emission principle as claimed in claims 1 to 5, and is characterized by comprising the following steps:
inputting a preset current to the exciting coil to enable the cutter to be detected to be placed in a preset alternating magnetic field;
collecting stress waves generated by the cutter to be tested under the influence of a magnetic field by using a test sensor; and
and transmitting the stress wave to a processor for processing, and outputting the residual stress level of the tool to be tested.
7. The cutter residual stress testing method based on the magnetoacoustic emission principle as claimed in claim 6, wherein the collecting stress waves generated by the cutter to be tested under the influence of a magnetic field by using a testing sensor comprises:
under the action of the alternating magnetic field, the crystal lattice of the cutter to be tested generates a magnetostriction phenomenon, relative displacement is generated in the two magnetic domains, the relative displacement causes the stress wave, and the stress wave is released;
and the test sensor detects the signal change of the cutter to be tested and collects the stress wave, wherein the test sensor is attached to the upper surface of the cutter to be tested by using a clamp.
8. The tool residual stress testing method based on the magnetoacoustic emission principle of claim 6, wherein the transmitting the stress wave to a processor for processing and outputting the residual stress level of the tool to be tested comprises:
transmitting the stress wave into the processor, and expressing the stress wave by using the inelastic strain tensor of the volume infinitesimal of the magnetic domain area of the cutter to be measured;
and processing the inelastic strain tensor to obtain MAE signal intensity, and evaluating the residual stress level of the tool to be measured according to the MAE signal intensity.
9. The method for testing the residual stress of the cutter based on the magnetoacoustic emission principle of claim 8, wherein the inelastic strain tensor and the MAE signal strength are related by the following formula:
wherein, VpAnd C is residual stress, C is a material parameter of the cutter to be measured, DeltaV is a volume infinitesimal element of the cutter to be measured in the magnetic domain region, Deltaepsilon is inelastic strain tensor, and tau is the time for increasing Deltaepsilon.
10. The method for testing the residual stress of the cutter based on the magnetoacoustic emission principle as claimed in claim 9, wherein the strength of the MAE signal is in a tensor direct relationship with the inelastic strain, and the strength of the MAE signal is in a direct relationship with the residual stress level of the cutter to be tested.
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