CN111289627A - Method for improving R-region phased array ultrasonic detection capability of complex-shaped component - Google Patents
Method for improving R-region phased array ultrasonic detection capability of complex-shaped component Download PDFInfo
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Abstract
A method for improving the ultrasonic detection capability of a phased array in an R area of a complex-shaped component belongs to the field of manufacturing and detection of high-end equipment. The method comprises the following steps: establishing a phased array ultrasonic detection model of the R region of the complex-shaped component; designing a phased array ultrasonic Surface Adaptive method (SAUL) combined with a receiving and focusing detection scheme; when the finite element model is used for reading the sound from each aperture array element to the corresponding focus, calculating a phased array ultrasonic detection receiving focusing rule of the R area of the complex-shaped component; and transmitting ultrasonic waves by using SAUL, receiving the scanning signals A in parallel by each array element, and carrying out receiving and focusing treatment to obtain an imaging result of combining a phased array ultrasonic surface adaptive method with receiving and focusing. The method improves the transverse resolution of the phased array ultrasonic detection of the R area of the complex-shaped member by combining with receiving focusing on the basis of SAUL, reduces detection noise, avoids artifacts and provides support for high-quality detection of the R area defects of the complex-shaped member.
Description
Technical Field
The invention relates to a method for improving the ultrasonic detection capability of a phased array in an R area of a complex-shaped component, and belongs to the field of manufacturing and detection of high-end equipment.
Background
With the development of industrial technology and the continuous improvement of structural design requirements, the geometric shapes of engineering components are more and more complex, and corner regions, namely R regions, generally exist. In the manufacturing and using process, the R region is easy to generate defects, and in order to ensure the manufacturing quality and the service safety of the component, a reliable nondestructive testing technology must be developed. At present, the phased array ultrasonic technology has great application potential in the aspect of detecting the defects of the R region of a component with a complex shape, but the problems of poor shape adaptability, poor defect resolution capability and the like still exist. The phased array ultrasonic Surface Adaptive method (SAUL) is an advanced imaging detection technology, can adapt to the complex shape of a component, realizes the vertical incidence of ultrasonic waves on the Surface of the component, and provides a new scheme for R-region defect detection. Research shows that SAUL has a good detection effect on single defects in the R region of a complex-shaped member, but when two or more defects exist in the circumferential direction of the R region at the same time, the detection effect is not ideal due to insufficient transverse resolution. Therefore, the development of the post-processing imaging method on the basis of SAUL has important significance for improving the R region multi-defect detection capability.
Disclosure of Invention
The invention provides a method for improving the ultrasonic detection capability of a phased array in an R area of a complex-shaped member. By using the method, the transverse detection resolution of SAUL can be improved, so that the detection capability of multiple defects in the R region is improved, and support is provided for high-quality detection of the complex-shaped member.
The technical scheme adopted by the invention is as follows: a method for improving the ultrasonic detection capability of a phased array in an R area of a complex-shaped member focuses a received signal on the basis of transmitting ultrasonic waves by using SAUL (ultrasonic Acoustic wave), and the ultrasonic detection capability of the phased array in the R area of the complex-shaped member is improved, the method comprises the following steps:
(1) establishing finite element simulation model
Measuring the density and elastic parameters of the sample, and obtaining the microstructure and geometric parameters of the sample by using a metallographic method; according to the specification of a phased array ultrasonic probe used for detection and ultrasonic excitation parameters including an array form, the number of wafers, the wafer spacing, and the main frequency, the frequency bandwidth and the phase of a transmitting signal, correspondingly setting in COMSOL Multiphysics finite element simulation software, and establishing an R area model of a complex-shaped component;
(2) SAUL time-law calculation
Based on the finite element simulation model in the step (1), not applying time delay to each array element of the phased array ultrasonic probe, transmitting ultrasonic waves for the first time, receiving an A scanning signal by each array element in parallel, reading the transit time of the ultrasonic waves from each array element to the surface of an R area, and calculating a time delay rule of transmitting the ultrasonic waves for the second time by the phased array ultrasonic probe; repeating the steps until the delay difference between the front and the back is less than 0.05 mu s, thereby obtaining the delay rule of SAUL transmitted ultrasonic waves;
(3) receive focus delay law calculation
The phased array ultrasonic probe is set as a linear array, and the total number of array elements isNThe number of array elements performing the receive focusing aperture ismAnd the step between the apertures is 1 array element, the total number of apertures used for focusing isN-m+ 1; setting the connection line of each focus and the center of the sample circle to pass through the aperture center, wherein the depth range of the focus is from the thickness of the sample 1/2 to the bottom surface; calculating the second step by using the finite element simulation model in the step (1)nThe time taken for the ultrasonic wave emitted by each array element to propagate to the focust n The corresponding receiving focusing delay rule has the calculation formula as follows:
wherein, Deltat i Is as followsnDelay of individual array elements;
(4) phased array ultrasonic imaging detection
Establishing an R region model of the complex-shaped component with a plurality of defects based on the finite element simulation model in the step (1); and (3) transmitting ultrasonic waves according to the delay rule obtained by calculation in the step (2), receiving the scanning signal A in parallel by each array element, applying the receiving focusing delay rule obtained by calculation in the step (3) to the scanning signal A, and drawing a sector diagram according to angle arrangement, so that an imaging result of SAUL combined receiving focusing is obtained, and the R-area defect imaging detection capability of the complex-shaped member is improved.
The invention has the beneficial effects that: the method for improving the R-area phased array ultrasonic detection capability of the complex-shaped member comprises the steps of establishing an R-area phased array ultrasonic detection model of the complex-shaped member, designing an SAUL combined receiving focusing detection scheme, calculating a receiving focusing rule of the R-area phased array ultrasonic detection of the complex-shaped member when a finite element model is used for reading sound of each aperture array element to a corresponding focus, transmitting ultrasonic waves by using the SAUL, receiving an A scanning signal in parallel by each array element and carrying out receiving focusing processing, and obtaining an imaging result of SAUL combined receiving focusing. The method improves the transverse resolution of the phased array ultrasonic detection of the R area of the complex-shaped member by combining with receiving focusing on the basis of SAUL, reduces detection noise, avoids the problem of artifact existing in multi-defect detection, and improves the defect imaging detection effect of the R area of the complex-shaped member.
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The present invention will be further explained below by taking the detection of the R region of a Carbon Fiber Reinforced Plastic (CFRP) T-type stringer sample as an example with reference to the accompanying drawings.
FIG. 1 is a finite element simulation model of the R region.
Fig. 2 is a diagram of the variation of delay law during SAUL iteration.
Fig. 3 is a schematic diagram of the R-zone receive focus position.
Figure 4 shows the signals received by the aperture 5 for each element at the focal point.
Figure 5 is the delay of the array elements of the aperture 5.
FIG. 6 is a finite element simulation model of an R region containing a double-layered defect.
FIG. 7 shows the SAUL detection result of the R-region circumferential double-delamination defect.
FIG. 8 is a SAUL detection result of a circumferential double-layered defect in an R region after receiving focusing.
Detailed Description
(1) Establishing finite element simulation model
Aiming at CFRP material T typeThe density of the stringer sample measured by Archimedes drainage method is 1542 kg/m3(ii) a The thickness of a single layer of the sample is 0.15 mm measured by a metallographic method, the total number of layers is 40, the R area part is 20 layers, and the sequence of the layers is [45 °/90 °/45 °/0 ° ]]5, the total thickness is 3.0 mm, the curvature radius of the R area is 5 mm, and the angle of the circle center is 90 degrees. Measuring sound velocities of CFRP material T-shaped stringers corresponding to different directions of a unidirectional board sample by adopting an ultrasonic liquid immersion back reflection method, then performing inversion by a simulated annealing algorithm to obtain an elastic stiffness matrix of a 90-degree direction layer of the unidirectional board, and performing Bond transformation to obtain elastic stiffness matrixes of 0-degree, 45-degree and-45-degree direction layers, wherein the elastic stiffness matrixes of the layers in four directions are as follows:
based on the above material properties and parameters, a defect-free R-zone model as shown in fig. 1 was created in COMSOL Multiphysics finite element simulation software. Wherein, the area above the sample is a coupling area, and the medium is water; the lower area is a filling area which simulates a T-shaped sample triangular area. The phased array ultrasonic probe is a linear array, the height of the center of a circle of an R area from the lower surface of the probe is 9.3 mm, the number of wafers is 32, the distance between the wafers is 0.6 mm, the main frequency of a transmitting signal is 2.25 MHz, the frequency bandwidth is 80%, and the phase is 0 degree. The probe is set to be a sound pressure boundary, the coupling region and the sample contact interface are set to be an acoustic-structure boundary, and the bottom is a free boundary.
(2) SAUL time-law calculation
Based on the finite element simulation model in the step (1), delay is not applied to each array element of the phased array ultrasonic probe (time delay 1) in fig. 2), ultrasonic waves are transmitted for the first time, each array element receives a scanning signal A in parallel, the transit time of the ultrasonic waves from each array element to the surface of the R area is read, the delay rule (time delay 2) of the phased array ultrasonic for transmitting the ultrasonic waves for the second time is calculated, the maximum difference value with the delay 1 is 0.0995 mu s and is larger than 0.05 mu s, delay is continuously calculated according to the steps to obtain delay 3, delay 4 and delay 5 in fig. 2, the maximum difference value of the last two delays is found to be 0.03 mu s and is smaller than 0.05 mu s, and the delay 5 is used as the delay rule of the ultrasonic waves transmitted by the UL SAs.
(3) Receive focus delay law calculation
In this example, the total number of array elements of the phased array ultrasonic linear array probe is 32, the number of array elements of the receiving focusing aperture is 6, the step between the apertures is 1 array element, and the total number of the apertures for focusing is 27. To ensure that each aperture focused acoustic beam is perpendicular to the surface of the R zone, each focal point is located through the aperture center, connected to the sample center, at a depth of focus at the thickness of the sample 1/2, as shown in fig. 3. The aperture 5 is taken as an example to illustrate the acquisition process of the receiving focusing delay law. Sequentially exciting array elements No. 5-10 contained in the aperture 5, and setting a point probe at a focus by utilizing COMSOL Multiphysics finite element simulation software to obtain an A scanning signal of ultrasonic waves transmitted to the focus position through water, wherein the A scanning signal is an ultrasonic signal received at the focus and transmitted by different array elements in the aperture 5, and FIG. 4 is an ultrasonic signal received at the focus. Reading the corresponding time of the longitudinal wave signal peak of No. 5 array element is the time for the ultrasonic wave transmitted by the array element to propagate to the focust 5 The time is 12.30 mu s, and the corresponding times of the array elements No. 6 to No. 10 can be respectively 12.08 mu s, 11.86 mu s, 11.66 mu s, 11.47 mu s and 11.28 mu s by the same method. Array element No. 5 corresponding delayΔt 5 Can be calculated from equation (2), i.e.:
the delay of each array element in the aperture 5 can then be calculated as shown in figure 5. Other 26 aperture-corresponding receive focus delay laws can be obtained in accordance with the above method.
(4) Phased array ultrasonic imaging detection
And (2) establishing a finite element simulation model containing double-layered defects on the basis of the model in the step (1), wherein as shown in fig. 6, the lengths of the two layered defects are both 2 mm and are respectively positioned at +/-25 degrees of the vertical direction of the R area, the defect depth is 1.5 mm from the upper surface of the sample, and the defect is set as a hard sound field boundary condition. The SAUL delay rule (delay 5) calculated in the step (2) is applied to the linear array to transmit ultrasonic waves, the array elements receive signals in parallel, the signals are arranged according to angles and drawn into a sector diagram, and the SAUL detection result is obtained and is shown in fig. 7. The noise signal in the image is found to be strong, and a more obvious pseudo-defect signal exists between two layered defects. And (3) applying the receiving focusing delay rule calculated in the step (3) to the A scanning signal received by the SAUL to obtain a 27 aperture signal. These signals are arranged angularly and plotted as a fan-shaped plot as shown in figure 8. Compared with the result of fig. 7, in fig. 8, except for the imaging of the sample surface and the two defects, no obvious noise signal exists, the pseudo-defect signal is eliminated, the maximum amplitude of the defect is improved by about 14 dB, and the detection quality is obviously improved.
Claims (1)
1. A method for improving the ultrasonic detection capability of a phased array in an R area of a complex-shaped component is characterized by comprising the following steps: on the basis of transmitting ultrasonic waves by using a phased array ultrasonic surface adaptation method, a received signal is focused, and the phased array ultrasonic detection capability of a complex-shaped member R area is improved, wherein the method comprises the following steps:
(1) establishing finite element simulation model
Measuring the density and elastic parameters of the sample, and obtaining the microstructure and geometric parameters of the sample by using a metallographic method; according to the specification of a phased array ultrasonic probe used for detection and ultrasonic excitation parameters including an array form, the number of wafers, the wafer spacing, and the main frequency, the frequency bandwidth and the phase of a transmitting signal, correspondingly setting in COMSOL Multiphysics finite element simulation software, and establishing an R area model of a complex-shaped component;
(2) phased array ultrasonic surface adaptation method time delay rule calculation
Based on the finite element simulation model in the step (1), not applying time delay to each array element of the phased array ultrasonic probe, transmitting ultrasonic waves for the first time, receiving an A scanning signal by each array element in parallel, reading the transit time of the ultrasonic waves from each array element to the surface of an R area, and calculating a time delay rule of transmitting the ultrasonic waves for the second time by the phased array ultrasonic probe; in the same way, until the delay difference between the front and the back is less than 0.05 mu s, so as to obtain the delay rule of transmitting the ultrasonic waves by the phased array ultrasonic surface adaptation method;
(3) receive focus delay law calculation
The phased array ultrasonic probe is set as a linear array, and the total number of array elements isNThe number of array elements performing the receive focusing aperture ismAnd the step between the apertures is 1 array element, the total number of apertures used for focusing isN-m+ 1; setting the connection line of each focus and the center of the sample circle to pass through the aperture center, wherein the depth range of the focus is from the thickness of the sample 1/2 to the bottom surface; calculating the second step by using the finite element simulation model in the step (1)nThe time taken for the ultrasonic wave emitted by each array element to propagate to the focust n The corresponding receiving focusing delay rule has the calculation formula as follows:
wherein, Deltat i Is as followsnDelay of individual array elements;
(4) phased array ultrasonic imaging detection
Establishing an R region model of the complex-shaped component with a plurality of defects based on the finite element simulation model in the step (1); and (3) transmitting ultrasonic waves according to the delay rule obtained by calculation in the step (2), receiving the scanning signal A in parallel by each array element, applying the receiving focusing delay rule obtained by calculation in the step (3) to the scanning signal A, and drawing a sector diagram according to angle arrangement, so that an imaging result of combining a phased array ultrasonic surface adaptation method with receiving focusing is obtained, and the R-area defect imaging detection capability of the complex-shaped member is improved.
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| CN112083067A (en) * | 2020-09-01 | 2020-12-15 | 大连理工大学 | R-zone acoustic ray tracing algorithm for curved-surface fiber-reinforced resin-based composite material multidirectional plate |
| CN113777165A (en) * | 2021-09-06 | 2021-12-10 | 哈尔滨工业大学 | Synthetic aperture dynamic focusing-based ultrasonic detection method for R region component defects and stress |
| CN113879558A (en) * | 2021-09-06 | 2022-01-04 | 国营芜湖机械厂 | Ultrasonic shape reconstruction method for T-shaped R region of wing |
| CN113899818A (en) * | 2021-09-06 | 2022-01-07 | 国营芜湖机械厂 | Ultrasonic detection method for R-region defects of T-shaped component for fuselage structure |
| CN113899479A (en) * | 2021-09-06 | 2022-01-07 | 国营芜湖机械厂 | Ultrasonic detection method for stress of T-shaped R region of fuselage structure |
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Cited By (9)
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| CN112083067A (en) * | 2020-09-01 | 2020-12-15 | 大连理工大学 | R-zone acoustic ray tracing algorithm for curved-surface fiber-reinforced resin-based composite material multidirectional plate |
| CN113777165A (en) * | 2021-09-06 | 2021-12-10 | 哈尔滨工业大学 | Synthetic aperture dynamic focusing-based ultrasonic detection method for R region component defects and stress |
| CN113879558A (en) * | 2021-09-06 | 2022-01-04 | 国营芜湖机械厂 | Ultrasonic shape reconstruction method for T-shaped R region of wing |
| CN113899818A (en) * | 2021-09-06 | 2022-01-07 | 国营芜湖机械厂 | Ultrasonic detection method for R-region defects of T-shaped component for fuselage structure |
| CN113899479A (en) * | 2021-09-06 | 2022-01-07 | 国营芜湖机械厂 | Ultrasonic detection method for stress of T-shaped R region of fuselage structure |
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| CN117589889A (en) * | 2024-01-19 | 2024-02-23 | 江苏省特种设备安全监督检验研究院 | Ultrasonic phased array microcrack detection method and system based on finite element model |
| CN117589889B (en) * | 2024-01-19 | 2024-04-02 | 江苏省特种设备安全监督检验研究院 | Ultrasonic phased array microcrack detection method and system based on finite element model |
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