CN111855448A - Metal material rolling contact fatigue test crack detection method - Google Patents

Metal material rolling contact fatigue test crack detection method Download PDF

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Publication number
CN111855448A
CN111855448A CN202010763480.2A CN202010763480A CN111855448A CN 111855448 A CN111855448 A CN 111855448A CN 202010763480 A CN202010763480 A CN 202010763480A CN 111855448 A CN111855448 A CN 111855448A
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sample
contact fatigue
rolling contact
electromagnetic induction
fatigue test
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CN111855448B (en
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张先国
郑立新
李满良
刘景超
蔡松涛
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Dongfeng Commercial Vehicle Co Ltd
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Dongfeng Commercial Vehicle Co Ltd
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N3/00Investigating strength properties of solid materials by application of mechanical stress
    • G01N3/32Investigating strength properties of solid materials by application of mechanical stress by applying repeated or pulsating forces
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N1/00Sampling; Preparing specimens for investigation
    • G01N1/28Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q
    • G01N1/286Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q involving mechanical work, e.g. chopping, disintegrating, compacting, homogenising
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N27/00Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
    • G01N27/72Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables
    • G01N27/82Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N3/00Investigating strength properties of solid materials by application of mechanical stress
    • G01N3/02Details
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2203/00Investigating strength properties of solid materials by application of mechanical stress
    • G01N2203/0001Type of application of the stress
    • G01N2203/0005Repeated or cyclic
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2203/00Investigating strength properties of solid materials by application of mechanical stress
    • G01N2203/0058Kind of property studied
    • G01N2203/0069Fatigue, creep, strain-stress relations or elastic constants
    • G01N2203/0073Fatigue
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2203/00Investigating strength properties of solid materials by application of mechanical stress
    • G01N2203/02Details not specific for a particular testing method
    • G01N2203/026Specifications of the specimen
    • G01N2203/0262Shape of the specimen
    • G01N2203/0266Cylindrical specimens
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2203/00Investigating strength properties of solid materials by application of mechanical stress
    • G01N2203/02Details not specific for a particular testing method
    • G01N2203/06Indicating or recording means; Sensing means
    • G01N2203/0617Electrical or magnetic indicating, recording or sensing means
    • G01N2203/0635Electrical or magnetic indicating, recording or sensing means using magnetic properties

Abstract

The invention discloses a metal material rolling contact fatigue test crack detection method, which comprises the following steps: 1) carrying out a rolling contact fatigue test on the calibration sample, simultaneously carrying out impedance detection, and collecting an electromagnetic induction impedance signal; 2) setting an electromagnetic induction parameter of an alarm threshold value according to an impedance detection result of the calibration sample; 3) changing the calibration sample into a sample to be tested to perform a rolling contact fatigue test, and simultaneously performing impedance detection; 4) and sending an alarm until the impedance signal of the sample to be tested is detected to be suddenly changed and reaches a set alarm threshold value, thus completing the test of the sample to be tested. The metal material rolling contact fatigue test crack detection method can accurately judge the occurrence of contact fatigue cracking in a metal material rolling contact fatigue test in real time, greatly improve the test efficiency and the detection precision and reduce the test workload.

Description

Metal material rolling contact fatigue test crack detection method
Technical Field
The invention belongs to the technical field of material testing, and particularly relates to a metal material rolling contact fatigue test crack detection method.
Background
The metal material rolling contact fatigue test is a test method for checking the material contact fatigue performance by adopting a cylindrical (or cylindrical bellied) sample and a accompanied sample through rolling contact, the surface contact fatigue failure detection of the sample is always a difficult point in the industry, and the problems of poor sensitivity, low test efficiency and the like exist respectively by adopting a method for monitoring a vibration signal or regularly and visually checking surface defects in the industry at present.
In the prior art, Chinese invention patent CN103424307B discloses a rolling contact fatigue acceleration test method for metal materials with small slip ratio, and the test method is characterized in that a test sample fails by stopping the test every 30 minutes and observing the surface of the tested sample until 1 test sample with 3mm appears2Or peeling off of 10mm2In, the macroscopic pitting pits exceed 10, or the total area rate of the pitting pits is more than 15%, the sample is judged to be invalid, the machine can be stopped at the moment, namely, the pitting is periodically checked to be invalid, the test is required to be stopped in the checking process, the observation is intermittent, the time for generating the cracks cannot be accurately judged, the tiny cracks are difficult to find by visual observation, the fatigue life accuracy of the sample is low, and the labor intensity of testers is high.
Chinese patent CN102494963A discloses a rolling contact fatigue testing machine for roller elements, which is used to terminate the test with an increased vibration output value when the test bar fails, i.e. to judge whether the test piece fails or not by the change of the vibration signal. The contact fatigue test is characterized by comprising a plurality of running parts such as motors, various bearings and the like, wherein the parts are vibration noise sources in the test, so that the background noise is overlarge, the failure judgment precision is influenced by the existence of system noise, and the accuracy of the test result is not high, so that the contact fatigue life of the metal material cannot be evaluated more accurately.
Therefore, it is necessary to develop a crack detection method for a rolling contact fatigue test of a metal material, so as to improve the accuracy of the test result and more accurately evaluate the contact fatigue life of the metal material.
Disclosure of Invention
The invention aims to solve the defects of the background technology and provide a metal material rolling contact fatigue test crack detection method.
In order to achieve the purpose, the invention adopts the technical scheme that: a metal material rolling contact fatigue test crack detection method comprises the following steps:
1) carrying out a rolling contact fatigue test on the calibration sample, simultaneously carrying out impedance detection, and collecting an electromagnetic induction impedance signal;
2) setting an electromagnetic induction parameter of an alarm threshold value according to an impedance detection result of the calibration sample;
3) changing the calibration sample into a sample to be tested to perform a rolling contact fatigue test, and simultaneously performing impedance detection;
4) and sending an alarm until the impedance signal of the sample to be tested is detected to be suddenly changed and reaches a set alarm threshold value, thus completing the test of the sample to be tested.
In the above technical scheme, in the step 1), the calibration sample is a sample with a pre-crack or a contact fatigue failure sample.
In the technical scheme, the prefabricated crack adopts a drill to punch or impress on a sample contact area, and the diameter of the prefabricated crack is 0.5-0.7 mm.
In the above technical scheme, in the step 1), the set rotation speed when the calibration sample is subjected to the rolling contact fatigue test is 800rpm to 2000 rpm.
In the above technical solution, in the step 1), an electromagnetic induction probe of an electromagnetic induction analyzer is fixed near a contact region of a sample to perform impedance detection.
In the technical scheme, the distance between the self-inductance coil of the electromagnetic induction probe and the surface of the calibration sample is 0.3-1.0 mm.
In the technical scheme, the inner ring of the head of the electromagnetic induction probe is provided with an arc concave surface which is arranged coaxially with the sample.
In the above technical solution, in the step 2), the specific method for setting the electromagnetic induction parameter of the alarm threshold value is as follows: observing the characteristic impedance waveform of the crack of the calibrated sample on a display screen of the electromagnetic induction analyzer, adjusting the size of an alarm area of the electromagnetic induction analyzer to enable the characteristic impedance waveform to reach the alarm area, starting alarming by an alarm of the electromagnetic induction analyzer, and storing the electromagnetic induction parameters as set parameters of an alarm threshold.
In the above technical scheme, in the step 3), the contact stress between the sample to be tested and the accompanying sample is 2800 to 3400MPa and the rotation speed is 800 to 2000rpm when the sample to be tested is subjected to the rolling contact fatigue test.
In the technical scheme, the electromagnetic induction analyzer can adopt a dual-channel signal electromagnetic induction analyzer to synchronously monitor the contact fatigue sample and the accompanying sample; or an electromagnetic induction analyzer of multi-channel signals can be adopted to simultaneously monitor a plurality of contact fatigue samples and accompanying samples.
In the technical scheme, the electromagnetic induction probe is composed of a shell and a self-induction coil framework wound inside the shell, the self-induction coil is wound on the magnetic core, the winding diameter of the coil is equal to the width of a sample contact area, the axis of the coil is dead against the center of the sample contact area during installation, and the distance between the end face of the coil and the surface of the sample is about 0.3-1.0 mm.
In the technical scheme, after the instrument is started, a self-inductance type coil in the electromagnetic induction probe carries alternating current, induced current is induced on the surface layer of a sample made of a metal material under the action of a coil magnetic field, if surface defects such as contact fatigue cracking and the like occur on the surface or the subsurface of the sample, the induced current influences the magnitude of the induced current, the counter-acting magnetic field of the induced current causes the impedance change of the probe, interference signals are removed from the change signals through filtering processing of the detection coil, the change signals are input into a computer of the detector through A/D conversion, and the amplitude and phase values of feedback signals, namely characteristic waveforms of contact fatigue cracks, can be displayed on a display screen.
Among the above-mentioned technical scheme, the demarcation sample and the sample that awaits measuring are cylindrical or cylinder bulge tripe type metal material sample, and the contact form is line contact or point contact between sample and the accompanying sample.
In the technical scheme, the calibration sample and the sample to be tested are made of alloy structural steel or bearing steel.
In the technical scheme, the electromagnetic induction setting parameters are the exciting frequency of the coil in the electromagnetic induction probe, the exciting frequency domain of the bearing steel is 130 kHz-170 kHz, and the exciting frequency domain of the alloy structural steel is 80 kHz-150 kHz.
In the technical scheme, the test sample to be tested is protected and connected when the rolling contact fatigue test is carried out in the step 3), the alarm connected with the electromagnetic induction analyzer is realized by the relay of the emergency stop switch of the contact fatigue test machine, and when the electromagnetic induction analyzer sends out an alarm signal, the relay is attracted to trigger the stop action of the contact fatigue test machine.
Compared with the prior art, the invention has the beneficial effects that:
the detection method provided by the invention is used for carrying out the rolling contact fatigue test of the metal material, the electromagnetic induction impedance signal acquired in the test process is used for judging, when the peak value of the impedance sudden change waveform reaches an alarm area, the shutdown protection of the testing machine is triggered, the occurrence of contact fatigue cracking in the rolling contact fatigue test of the metal material can be accurately judged in real time, the test efficiency and the detection precision are greatly improved, the test workload is reduced, and the automatic detection problem of the contact fatigue failure of the surface of the sample in the rolling contact fatigue test of the metal material is solved.
Drawings
FIG. 1 is a schematic structural diagram of an electromagnetic induction analyzer for impedance detection;
FIG. 2 is a schematic diagram of a control signal structure of the electromagnetic induction probe;
FIG. 3 is a graph showing the results of impedance detection in example 1;
FIG. 4 is a schematic view of surface contact fatigue cracking of the test piece of example 1;
FIG. 5 is a graph showing the results of impedance detection in example 2;
FIG. 6 is a schematic view of the surface contact fatigue cracking of the test piece of example 3;
in the figure: 1-electromagnetic induction analyzer, 2-electromagnetic induction probe.
Detailed Description
The invention will be further described in detail with reference to the following drawings and specific examples, which are not intended to limit the invention, but are for clear understanding.
Example 1:
according to the crack detection method for the metal material rolling contact fatigue test, a sample to be detected is a cylindrical sample with the diameter of 25.5mm, a test sample is a disc-shaped sample with the diameter of 75mm, the sample materials are GCr15 bearing steel, induction quenching treatment is carried out, and the width of a contact area is 5 mm. As shown in figure 1, an electromagnetic induction probe 2 of an electromagnetic induction analyzer 1 is fixed on a table top of a contact fatigue testing machine, the center of the electromagnetic induction probe is over against the surface of a contact area of a sample, the end face of a self-induction coil of the electromagnetic induction probe is 0.5mm away from the surface of the sample, and the diameter of the coil is 5 mm. Firstly, a GCr15 material calibration sample with a 0.5mm diameter prefabricated crack is used for calibration, an electromagnetic induction analyzer is started for impedance signal monitoring, a contact fatigue testing machine is started to enable the rotation speed of the calibration sample to reach 1000rpm, the excitation signal frequency of the electromagnetic induction analyzer is adjusted to 150kHz, the instrument screen displays a clear prefabricated crack impedance characteristic waveform, the size of an alarm area is set to enable a wave crest to just trigger alarm, and protection calibration is completed. The calibration sample is replaced by a sample to be tested and started, the contact stress of the sample to be tested and the accompanying sample is set to be 3400MPa, the rotating speed is 1000rpm, the contact area is lubricated by using 20# engine oil, a protection switch is turned on, as shown in figure 3, an electromagnetic induction alarm signal appears after 140 ten thousand cycles, the contact fatigue testing machine is automatically stopped, the sample is disassembled and inspected, and the contact fatigue crack on the surface of the sample is observed as shown in figure 4.
Example 2:
according to the crack detection method for the metal material rolling contact fatigue test, a sample to be detected is a cylindrical sample with the diameter of 25.5mm, a test sample is a disc-shaped sample with the diameter of 75mm, the sample material is 20CrMnTi low-carbon alloy structural steel, and the sample is subjected to carburizing and quenching treatment, wherein the width of a contact area is 5 mm. As shown in figure 1, an electromagnetic induction probe is fixed on the table top of a contact fatigue testing machine, the center of the electromagnetic induction probe is just opposite to the surface of a contact area of a sample, the end face of a self-induction coil of the electromagnetic induction probe is 0.5mm away from the surface of the sample, and the diameter of the coil is 5 mm. Firstly, a 20CrMnTi material calibration sample with a 0.5mm diameter prefabricated crack is used for calibration, an electromagnetic induction analyzer is started for impedance signal monitoring, a contact fatigue testing machine is started to enable the rotation speed of the calibration sample to reach 1000rpm, the excitation signal frequency of the electromagnetic induction analyzer is adjusted to 133kHz, an instrument screen displays a clear prefabricated crack impedance characteristic waveform, the size of an alarm area is set to enable a wave crest to just trigger alarm, and protection calibration is completed. The calibration sample is replaced by a sample to be tested and started, the contact stress of the sample to be tested and the accompanying sample is set to be 2800MPa, the rotating speed is 1000rpm, the contact area is lubricated by MT-1 gear oil, a protection switch is turned on, as shown in figure 5, an electromagnetic induction alarm signal appears after 27 ten thousand cycles, the contact fatigue testing machine is automatically stopped, the sample is disassembled and inspected, and the contact fatigue crack on the surface of the sample is observed as shown in figure 6.
Example 3:
according to the crack detection method for the metal material rolling contact fatigue test, a sample to be detected is a cylindrical sample with the diameter of 25.5mm, a test sample is a disc-shaped sample with the diameter of 75mm, the sample material is 20CrMnTi low-carbon alloy structural steel, and the sample is subjected to carburizing and quenching treatment, wherein the width of a contact area is 5 mm. As shown in figure 1, an electromagnetic induction probe is fixed on the table top of a contact fatigue testing machine, the center of the electromagnetic induction probe is just opposite to the surface of a contact area of a sample, the end face of a self-induction coil of the electromagnetic induction probe is 0.3mm away from the surface of the sample, and the diameter of the coil is 3 mm. Firstly, a 20CrMnTi material calibration sample with a 0.5mm diameter prefabricated crack is used for calibration, an electromagnetic induction analyzer is started for impedance signal monitoring, a contact fatigue testing machine is started to enable the rotation speed of the calibration sample to reach 800rpm, the excitation signal frequency of the electromagnetic induction analyzer is adjusted to 140kHz, an instrument screen displays a clear prefabricated crack impedance characteristic waveform, the size of an alarm area is set to enable a wave crest to just trigger alarm, and protection calibration is completed. The calibration sample is replaced by a sample to be tested and started, the contact stress of the sample to be tested and the accompanying sample is set to be 2800MPa, the rotating speed is 800rpm, the contact area is lubricated by MT-1 gear oil, a protection switch is turned on, an electromagnetic induction alarm signal appears, the contact fatigue testing machine is automatically stopped, the sample is dismounted and inspected, and the contact fatigue crack on the surface of the sample is observed.
Example 4:
according to the crack detection method for the metal material rolling contact fatigue test, a sample to be detected is a cylindrical sample with the diameter of 25.5mm, a test sample is a disc-shaped sample with the diameter of 75mm, the sample material is 20CrMnTi low-carbon alloy structural steel, and the sample is subjected to carburizing and quenching treatment, wherein the width of a contact area is 1 mm. As shown in figure 1, an electromagnetic induction probe is fixed on the table top of a contact fatigue testing machine, the center of the electromagnetic induction probe is just opposite to the surface of a contact area of a sample, the end face of a self-induction coil of the electromagnetic induction probe is 0.1mm away from the surface of the sample, and the diameter of the coil is 1 mm. Firstly, a 20CrMnTi material calibration sample with a 0.5mm diameter prefabricated crack is used for calibration, an electromagnetic induction analyzer is started for impedance signal monitoring, a contact fatigue testing machine is started to enable the rotation speed of the calibration sample to reach 2000rpm, the excitation signal frequency of the electromagnetic induction analyzer is adjusted to 160kHz, an instrument screen displays a clear prefabricated crack impedance characteristic waveform, the size of an alarm area is set to enable a wave peak to just trigger alarm, and protection calibration is completed. The calibration sample is replaced by a sample to be tested and started, the contact stress of the sample to be tested and the accompanying sample is set to be 3400MPa, the rotating speed is 2000rpm, the contact area is lubricated by MT-1 gear oil, a protection switch is turned on, an electromagnetic induction alarm signal appears, the contact fatigue testing machine is automatically stopped, the sample is detached for inspection, and the contact fatigue crack on the surface of the sample is observed.
The above description is only for the specific embodiments of the present invention, and it should be noted that the remaining detailed descriptions are related to the prior art, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the protection scope of the present invention.

Claims (9)

1. A metal material rolling contact fatigue test crack detection method is characterized by comprising the following steps: the method comprises the following steps:
1) carrying out a rolling contact fatigue test on the calibration sample, simultaneously carrying out impedance detection, and collecting an electromagnetic induction impedance signal;
2) setting an electromagnetic induction parameter of an alarm threshold value according to an impedance detection result of the calibration sample;
3) changing the calibration sample into a sample to be tested to perform a rolling contact fatigue test, and simultaneously performing impedance detection;
4) and sending an alarm until the impedance signal of the sample to be tested is detected to be suddenly changed and reaches a set alarm threshold value, thus completing the test of the sample to be tested.
2. The metallic material rolling contact fatigue test crack detection method of claim 1, characterized in that: in the step 1), the calibration sample is a sample with a pre-crack or a contact fatigue failure sample.
3. The metallic material rolling contact fatigue test crack detection method of claim 2, characterized in that: the prefabricated crack adopts a drill to punch or impress on a sample contact area, and the diameter of the prefabricated crack is 0.5 mm-0.7 mm.
4. The metallic material rolling contact fatigue test crack detection method of claim 1, characterized in that: in the step 1), the set rotating speed is 800 rpm-2000 rpm when the calibration sample is subjected to the rolling contact fatigue test.
5. The metallic material rolling contact fatigue test crack detection method of claim 1, characterized in that: in the step 1), an electromagnetic induction probe (2) of the electromagnetic induction analyzer (1) is fixed near a contact area of the sample for impedance detection.
6. The metallic material rolling contact fatigue test crack detection method of claim 5, characterized in that: the distance between the self-inductance coil of the electromagnetic induction probe (2) and the surface of the calibration sample is 0.3 mm-1.0 mm.
7. The metallic material rolling contact fatigue test crack detection method of claim 5, characterized in that: the inner ring of the head of the electromagnetic induction probe (2) is provided with an arc concave surface which is arranged coaxially with the sample.
8. The metallic material rolling contact fatigue test crack detection method of claim 1, characterized in that: in the step 2), the specific method for setting the electromagnetic induction parameters of the alarm threshold value comprises the following steps: observing the characteristic impedance waveform of the crack of the calibrated sample on a display screen of the electromagnetic induction analyzer (1), adjusting the size of an alarm area of the electromagnetic induction analyzer (1) to enable the characteristic impedance waveform to reach the alarm area, starting alarming by an alarm of the electromagnetic induction analyzer (1), and storing the electromagnetic induction parameters as set parameters of an alarm threshold.
9. The metallic material rolling contact fatigue test crack detection method of claim 1, characterized in that: in the step 3), the contact stress of the sample to be tested and the accompanied sample is set to be 2800 MPa-3400 MPa when the sample to be tested is subjected to the rolling contact fatigue test, and the rotating speed is 800 rpm-2000 rpm.
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