CN112629728A - Aluminum alloy residual stress testing device and method based on eddy current - Google Patents
Aluminum alloy residual stress testing device and method based on eddy current Download PDFInfo
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- CN112629728A CN112629728A CN202011514959.9A CN202011514959A CN112629728A CN 112629728 A CN112629728 A CN 112629728A CN 202011514959 A CN202011514959 A CN 202011514959A CN 112629728 A CN112629728 A CN 112629728A
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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
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/72—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables
- G01N27/82—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws
- G01N27/90—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws using eddy currents
- G01N27/9046—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws using eddy currents by analysing electrical signals
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Abstract
The invention belongs to the technical field of testing, and particularly relates to an aluminum alloy residual stress testing device based on eddy current and a testing method thereof, wherein the device comprises a high-precision phase-locked amplifier, a computer for controlling the phase-locked amplifier and two eddy current sensor probes for acquiring signals; the phase-locked amplifier is used for sending out an excitation signal and simultaneously measuring a feedback eddy current signal; one eddy current sensor probe is used as a reference probe for detecting a residual stress-free standard part of the aluminum alloy; and the other eddy current sensor probe is used as a detection probe for detecting the aluminum alloy detected sample. The invention has simple structure, can avoid systematic errors caused by excessively complicated equipment connecting structure as much as possible, does not need to consume a coupling agent, has accurate and reliable result and certain detection depth, is suitable for large-scale complicated structural parts, and can realize the purpose by simply connecting a plurality of parts.
Description
Technical Field
The invention belongs to the technical field of testing, and particularly relates to a device and a method for testing residual stress of an aluminum alloy based on eddy current.
Background
The detection of residual stress has been carried out for many years both at home and abroad, and the measuring method can be divided into a mechanical measuring method and a physical measuring method. Mechanical measurements require stress relief by local separation or splitting, which can cause some damage or even destruction of the workpiece, typically by grooving and drilling. The physical measurement methods mainly include a ray method, a magnetic method and an ultrasonic method, and all belong to nondestructive testing methods. The theory of the ray method is perfect, but the application of the method is greatly limited due to ray damage and the fact that only the surface stress can be measured; the magnetic method is used for measuring according to the change relation between stress and a magnetization curve in the ferromagnetic body magnetic saturation process and is only used in a certain range; the ultrasonic method needs to be perfected in the aspects of ultrasonic transverse wave transducers, transverse wave coupling agents and the like. At present, the methods cannot be well applied to the on-line detection and feedback of the residual stress in the manufacturing process of large-scale complex aluminum alloy components. The principle of the eddy current testing method is that an alternating current coil induces a conductive material to generate induced eddy current, and then the eddy current is wound around a magnetic field to change the impedance of a detection coil, so that the residual stress and the stress direction of the material can be quickly and accurately reflected by measuring the change of the impedance of the detection coil and establishing an incidence relation by combining the piezoresistive strain effect of the material. Compared with other detection technologies, the eddy current detection has the advantages of low cost, simple equipment, convenience in operation, high data comprehensiveness, convenience in on-line monitoring and the like, and is an effective means and method for on-line detection of residual stress in the manufacturing process of large-scale complex aluminum alloy components.
At present, a conventional eddy current-based aluminum alloy plate residual stress detection device is generally composed of a signal generator, a power amplifier, a bridge circuit, a differential amplifier, a preamplifier and a PCI data acquisition card. The signal generator sends out an excitation signal, and the excitation signal is amplified by the power amplifier and then is connected to the testing coil. And 2 identical rectangular coils, one of which is used as a detection coil and the other is used as a reference coil, are respectively placed on two bridge arms of the bridge circuit to perform reference test on the two sample pieces. And the differential amplifier is used for carrying out differential and amplification on the test data of the two coils. Then inputting the data into a preamplifier, and further collecting the obtained data by a PCI data acquisition card. The related equipment structure is more complex; signal output and data acquisition are not precise enough; the related amplification steps are more, and systematic errors are easily caused.
Disclosure of Invention
In order to solve the defects and shortcomings in the prior art, the invention provides the eddy current-based aluminum alloy residual stress testing device and the testing method thereof, which have the advantages of simple structure, capability of avoiding systematic errors caused by excessively complicated equipment connecting structures as much as possible, no need of consuming a coupling agent, accurate and reliable results, certain detection depth, suitability for large complicated structural parts and capability of realizing simple connection of a plurality of parts.
The technical scheme of the invention is as follows: an aluminum alloy residual stress testing device based on eddy current comprises a high-precision phase-locked amplifier, a computer for controlling the phase-locked amplifier and two eddy current sensor probes for acquiring signals;
the phase-locked amplifier is used for sending out an excitation signal and simultaneously measuring a feedback eddy current signal;
one eddy current sensor probe is used as a reference probe for detecting a residual stress-free standard part of the aluminum alloy;
and the other eddy current sensor probe is used as a detection probe for detecting the aluminum alloy detected sample.
The invention has simple structure, can avoid systematic errors caused by excessively complicated equipment connecting structure as much as possible, does not need to consume a coupling agent, has accurate and reliable result and certain detection depth, is suitable for large-scale complicated structural parts, and can realize the purpose by simply connecting a plurality of parts.
Preferably, the operation mode of the phase-locked amplifier is current sine wave excitation, the excitation frequency of the phase-locked amplifier is preset to be 500Hz, and the sampling frequency of the phase-locked amplifier is preset to be 500 kHz.
The excitation frequency of the phase-locked amplifier can be modified according to the specific feedback condition of the tested sample.
Preferably, a signal input module, a signal output module, a digital I/O module and a timing counting module are arranged in the lock-in amplifier.
Preferably, a signal amplifier is connected between the lock-in amplifier and the two eddy current sensor probes, and the signal amplifier amplifies the voltage input to the two eddy current sensor probes.
Because the eddy current in the metal has the skin effect, the condition that the detection depth is too shallow is easily caused, and for the detection depth requirement higher than several millimeters, a signal amplifier is used for amplifying the voltage input into the probe of the sensor.
Preferably, the two eddy current sensor probes each comprise an excitation coil and a magnetic sensor, wherein the excitation coil is designed in a cylindrical shape, the inner diameter of the excitation coil is 4mm, 20 turns of each layer of enameled copper wire with the wire diameter of 0.15mm are adopted, and the number of the 5 layers of enameled copper wire is 100.
Preferably, the magnetic sensor adopts a hall sensor UGN3503, and is placed at a position 0.5mm away from the measured piece to detect the vertical component of the magnetic field.
The eddy current sensor probe calculates the residual stress by feeding back the coil impedance change information in the phase-locked amplifier, and the Hall sensor is an optional verification component as the detection device of the vertical component of the magnetic field.
A test method of an aluminum alloy residual stress test device based on eddy current comprises the following steps:
1) the computer controls the phase-locked amplifier to send out an excitation signal to the aluminum alloy sample piece to be tested and the aluminum alloy standard piece without residual stress;
2) the eddy current sensor probe used as a reference probe detects the standard part without residual stress of the aluminum alloy, and the eddy current sensor probe used as a detection probe detects the sample to be detected of the aluminum alloy, so that a differential signal is formed and is collected and analyzed by a phase-locked amplifier;
3) the calculation of the residual stress by the two eddy current sensor probes is realized by feeding back coil impedance change information in the phase-locked amplifier, and meanwhile, the calculation of the residual stress is verified;
4) and finally, reading the data of the phase-locked amplifier by the computer.
Preferably, the lock-in amplifier in step 1) is a device capable of separating a specific carrier frequency signal from an environment with a signal-to-noise ratio of less than or equal to-60 dB, and the precision of the device ensures stable output of the excitation signal and accurate measurement of the feedback signal of the system.
Preferably, stress detection of different depths of the sample to be detected can be achieved in the step 1) through selection and adjustment of the signal amplifier.
Preferably, the calculation of the residual stress is verified in the step 3) through the selection of the hall sensor, so as to ensure the accuracy of the detection system.
The invention has simple structure, can avoid systematic errors caused by excessively complicated equipment connecting structure as much as possible, does not need to consume a coupling agent, has accurate and reliable result and certain detection depth, is suitable for large-scale complicated structural parts, and can realize the purpose by simply connecting a plurality of parts.
Drawings
FIG. 1 is a block diagram of the connection of components of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the attached drawings, but the present invention is not limited thereto.
As shown in fig. 1, an eddy current based aluminum alloy residual stress testing device comprises a high-precision lock-in amplifier, a computer for controlling the lock-in amplifier, and two eddy current sensor probes for acquiring signals;
the phase-locked amplifier is used for sending out an excitation signal and simultaneously measuring a feedback eddy current signal;
one eddy current sensor probe is used as a reference probe for detecting a residual stress-free standard part of the aluminum alloy;
and the other eddy current sensor probe is used as a detection probe for detecting the aluminum alloy detected sample.
The working mode of the phase-locked amplifier is current sine wave excitation, the excitation frequency is preset to be 500Hz, and the sampling frequency is preset to be 500 kHz. The phase-locked amplifier is internally provided with a signal input module, a signal output module, a digital I/O module and a timing counting module. And a signal amplifier is connected between the phase-locked amplifier and the two eddy current sensor probes and is used for amplifying the voltage input into the two turbine sensor probes. The two eddy current sensor probes comprise excitation coils and magnetic sensors, wherein the excitation coils are designed in a cylindrical mode, the inner diameter of each excitation coil is 4mm, 20 turns of each layer of enameled copper wires with the wire diameter of 0.15mm are adopted, and the number of the 5 layers of enameled copper wires is 100. The magnetic sensor adopts a Hall sensor UGN3503, is placed at a position 0.5mm away from a measured piece and is used for detecting the vertical component of a magnetic field.
A test method of an aluminum alloy residual stress test device based on eddy current comprises the following steps:
1) the computer controls the phase-locked amplifier to send out an excitation signal to the aluminum alloy sample piece to be tested and the aluminum alloy standard piece without residual stress;
2) the eddy current sensor probe used as a reference probe detects the standard part without residual stress of the aluminum alloy, and the eddy current sensor probe used as a detection probe detects the sample to be detected of the aluminum alloy, so that a differential signal is formed and is collected and analyzed by a phase-locked amplifier;
3) the calculation of the residual stress by the two eddy current sensor probes is realized by feeding back coil impedance change information in the phase-locked amplifier, and meanwhile, the calculation of the residual stress is verified;
4) and finally, reading the data of the phase-locked amplifier by the computer.
The phase-locked amplifier in the step 1) is a device which can separate a specific carrier frequency signal from an environment with a signal-to-noise ratio of less than or equal to-60 dB, and the precision degree of the device ensures the stable output of the excitation signal and the accurate measurement of the feedback signal of the system. In the step 1), stress detection of different depths of the sample to be detected can be achieved through selection and adjustment of the signal amplifier. And 3) verifying the calculation of the residual stress by selecting the Hall sensor so as to ensure the accuracy of the detection system.
The eddy current effect in the present invention refers to a phenomenon in which a metal conductor generates a vortex-like induced current when placed in a changing magnetic field. When the two ends of the exciting coil are electrified with alternating current I1An alternating magnetic field B is generated in the exciting coil1In the conductor test piece due to B1Inducing eddy currents I2，I2Influenced by the conductivity and permeability of the test piece, and the eddy current I2Counter-acting magnetic field B2And the impedance of the detection coil can be changed, so that the conductivity, the defect and the like of the tested piece can be indirectly derived by measuring the change of the impedance of the detection coil.
The invention has the following specific advantages: 1. the device mainly comprises a phase-locked amplifier and a sensor probe, wherein the phase-locked amplifier is controlled and data is read by a computer, and special requirement functions are realized by an optional signal amplifier and a Hall sensor; 2. due to the simple structure, systematic errors caused by excessively complicated equipment connecting joints can be avoided as much as possible; 3. the phase-locked amplifier is a device capable of separating a specific carrier frequency signal from an environment with great interference (the signal-to-noise ratio can be as low as-60 dB or even lower), and the precision degree of the phase-locked amplifier ensures the stable output of an excitation signal and the accurate measurement of a feedback signal of the system; 4. the stress detection of different depths of the sample to be detected is achieved by selecting and adjusting the signal amplifier; 5. and the calculation of the residual stress is verified by selecting the Hall sensor so as to ensure the accuracy of the detection system.
The invention uses the phase-locked amplifier and the round coil sensor probe to form a residual stress detection device with high precision, high reliability, simple structure and small system error, the optional signal amplifier adjusts the detection depth, and the optional Hall sensor detects the magnetic field component in the vertical direction to verify the calculation of the residual stress.
Claims (10)
1. The utility model provides an aluminum alloy residual stress testing arrangement based on vortex which characterized in that: the device comprises a high-precision phase-locked amplifier, a computer for controlling the phase-locked amplifier and two eddy current sensor probes for acquiring signals;
the phase-locked amplifier is used for sending out an excitation signal and simultaneously measuring a feedback eddy current signal;
one eddy current sensor probe is used as a reference probe for detecting a residual stress-free standard part of the aluminum alloy;
and the other eddy current sensor probe is used as a detection probe for detecting the aluminum alloy detected sample.
2. The aluminum alloy residual stress testing device based on eddy current as recited in claim 1, wherein: the working mode of the phase-locked amplifier is current sine wave excitation, the excitation frequency is preset to be 500Hz, and the sampling frequency is preset to be 500 kHz.
3. The aluminum alloy residual stress testing device based on eddy current as recited in claim 2, wherein: the phase-locked amplifier is internally provided with a signal input module, a signal output module, a digital I/O module and a timing counting module.
4. The aluminum alloy residual stress testing device based on eddy current as recited in claim 1, wherein: and a signal amplifier is connected between the phase-locked amplifier and the two eddy current sensor probes and is used for amplifying the voltage input into the two turbine sensor probes.
5. The aluminum alloy residual stress testing device based on eddy current as recited in claim 1, wherein: the two eddy current sensor probes comprise excitation coils and magnetic sensors, wherein the excitation coils are designed in a cylindrical mode, the inner diameter of each excitation coil is 4mm, 20 turns of each layer of enameled copper wires with the wire diameter of 0.15mm are adopted, and the number of the 5 layers of enameled copper wires is 100.
6. The aluminum alloy residual stress testing device based on eddy current as recited in claim 5, wherein: the magnetic sensor is a Hall sensor UGN3503, is placed at a position 0.5mm away from a measured piece and is used for detecting the vertical component of a magnetic field.
7. The testing method of the eddy current-based aluminum alloy residual stress testing device according to claim 6, characterized in that: the method comprises the following steps:
1) the computer controls the phase-locked amplifier to send out an excitation signal to the aluminum alloy sample piece to be tested and the aluminum alloy standard piece without residual stress;
2) the eddy current sensor probe used as a reference probe detects the standard part without residual stress of the aluminum alloy, and the eddy current sensor probe used as a detection probe detects the sample to be detected of the aluminum alloy, so that a differential signal is formed and is collected and analyzed by a phase-locked amplifier;
3) the calculation of the residual stress by the two eddy current sensor probes is realized by feeding back coil impedance change information in the phase-locked amplifier, and meanwhile, the calculation of the residual stress is verified;
4) and finally, reading the data of the phase-locked amplifier by the computer.
8. The testing method of the eddy current-based aluminum alloy residual stress testing device according to claim 7, characterized in that: the phase-locked amplifier in the step 1) is a device capable of separating a specific carrier frequency signal from an environment with a signal-to-noise ratio of less than or equal to-60 dB, and the precision degree of the device ensures stable output of an excitation signal and accurate measurement of a feedback signal of the system.
9. The testing method of the eddy current-based aluminum alloy residual stress testing device according to claim 7, characterized in that: in the step 1), stress detection of different depths of the sample to be detected can be achieved through selection and adjustment of the signal amplifier.
10. The testing method of the eddy current-based aluminum alloy residual stress testing device according to claim 7, characterized in that: and 3) verifying the calculation of the residual stress by selecting the Hall sensor in the step 3) so as to ensure the accuracy of the detection system.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113418984A (en) * | 2021-08-05 | 2021-09-21 | 重庆大学 | Become oar bearing high strength steel crack detecting system |
| CN116147808A (en) * | 2023-01-13 | 2023-05-23 | 南京航空航天大学 | In-situ detection device and detection method for residual stress of complex ferromagnetic component |
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