CN112748188A - Test method for detecting fatigue crack detection capability of axle of high-speed train by ultrasonic flaw detection - Google Patents
Test method for detecting fatigue crack detection capability of axle of high-speed train by ultrasonic flaw detection Download PDFInfo
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- CN112748188A CN112748188A CN202011601287.5A CN202011601287A CN112748188A CN 112748188 A CN112748188 A CN 112748188A CN 202011601287 A CN202011601287 A CN 202011601287A CN 112748188 A CN112748188 A CN 112748188A
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- fatigue crack
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/30—Arrangements for calibrating or comparing, e.g. with standard objects
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/02—Indexing codes associated with the analysed material
- G01N2291/023—Solids
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/02—Indexing codes associated with the analysed material
- G01N2291/028—Material parameters
- G01N2291/0289—Internal structure, e.g. defects, grain size, texture
Abstract
The invention provides a test method for detecting the fatigue crack detection capability of an axle of a high-speed train by ultrasonic flaw detection, which comprises the following steps: firstly, preparing a test sample shaft containing fatigue cracks; ② fatigue crack exposure: exposing the fatigue crack to an outer surface of the test specimen shaft; thirdly, ultrasonic flaw detection: carrying out flaw detection test on the fatigue crack of the test sample shaft by adopting an automatic flaw detection and/or manual flaw detection means; if the fatigue crack can be detected, performing a fourth step, and if the fatigue crack cannot be detected, performing a fifth step; turning: turning the test sample shaft to a certain depth at the fatigue crack position, and returning to the fourth step; opening the cross section: the fatigue crack sections were opened and the remaining fatigue crack depths were measured. By the test method, the limit detection depth value of the fatigue crack of the axle of the high-speed train by utilizing ultrasonic flaw detection can be accurately known, data support is provided for the regular detection of the axle, and the detection accuracy is improved.
Description
Technical Field
The invention relates to a test method for researching the detection capability of ultrasonic flaw detection on fatigue cracks of high-speed train axles, which is suitable for the railway industry, and particularly relates to a method for detecting the fatigue cracks of the axles at different positions, different depths and different lengths by automatic flaw detection and manual flaw detection respectively, and obtaining the detection capability of the ultrasonic flaw detection on the fatigue cracks by comparing the required gain value with the crack depth.
Background
The axle is an important safety part of the high-speed train, and the quality of the axle is directly related to the overhaul period and the operation safety of the rolling stock. The axle has some inherent defects due to factors such as poor axle material and improper heat treatment process. Meanwhile, surface defects can be generated due to accidental factors such as flyrock impact, scratching and the like in the running process. In addition, the steel plate is subjected to fatigue loading action for a long time in operation, and fatigue cracks are easy to grow in a stress concentration area, so that the driving safety is endangered.
Accordingly, the axle needs to be inspected after a certain history of operation, including non-destructive inspection. At present, the nondestructive inspection of the axle of the high-speed train mainly adopts the following methods: ultrasonic flaw detection, magnetic particle flaw detection and eddy current flaw detection, wherein the ultrasonic flaw detection is a main means for measuring fatigue cracks in an axle.
The fatigue crack in the axle has depth, when the depth of the crack is smaller, the ultrasonic flaw detection cannot detect the existence of the crack, and the critical value of the crack depth which can be measured by the ultrasonic flaw detector is a difficult problem which is always troubling detection workers and is also a technical problem which is required to be solved by the invention.
Disclosure of Invention
The invention provides a test method for detecting capability of ultrasonic flaw detection on fatigue cracks of high-speed train axles, aiming at finding out a crack depth critical value which can be measured by an ultrasonic flaw detector by the method, accurately knowing the capability of ultrasonic flaw detection on the fatigue cracks of the high-speed train axles, providing data support for periodic axle detection and improving the detection accuracy.
In order to achieve the purpose, the invention adopts the technical scheme that:
a test method for detecting the fatigue crack detection capability of an axle of a high-speed train by ultrasonic flaw detection is characterized by comprising the following steps:
firstly, preparing a test sample shaft containing fatigue cracks;
wherein, the test sample shaft containing the fatigue crack is obtained by adopting a method of manufacturing artificial defects on the test sample shaft by an artificial manufacturing method, and then applying stress to generate the fatigue crack at the artificial defects and extending
② fatigue crack exposure:
removing artificial defects, and exposing fatigue cracks on the outer surface of the test sample shaft;
thirdly, ultrasonic flaw detection: carrying out flaw detection test on the fatigue crack of the test sample shaft by adopting an automatic flaw detection and/or manual flaw detection means;
if the fatigue crack can be detected, performing a fourth step, and if the fatigue crack cannot be detected, performing a fifth step;
turning: turning the test sample shaft to a certain depth at the fatigue crack position, and returning to the third step;
opening the cross section: the fatigue crack sections were opened and the remaining fatigue crack depths were measured.
The method for testing the fatigue crack detection capability of the ultrasonic flaw detection on the axle of the high-speed train comprises the following steps of cutting the artificial defects of the test sample axle to remove the artificial defects until only the fatigue crack is remained.
The method for testing the fatigue crack detection capability of the ultrasonic flaw detection on the axle of the high-speed train comprises the following steps of arranging the artificial flaws on straight sections and/or circular arc parts of the axle of a test sample.
The test method for the fatigue crack detection capability of the ultrasonic flaw detection on the axle of the high-speed train is characterized in that the artificial flaws are 2, 3, 4 or more cutting seams which are arranged at intervals in the circumferential direction.
The method for testing the fatigue crack detection capability of the ultrasonic flaw detection on the axle of the high-speed train comprises the following steps of loading nominal stress on the cross section of an artificial defect by adopting a full-size axle test bed, and enabling fatigue cracks to be generated on two sides of the artificial defect and extend.
The method for testing the fatigue crack detection capability of the ultrasonic flaw detection on the axle of the high-speed train comprises the step three of carrying out flaw detection test on the fatigue crack of the test sample axle by using automatic hollow axle ultrasonic flaw detection equipment and a hollow axle flaw detection standard test block.
The test method for the detection capability of the ultrasonic flaw detection on the fatigue crack of the axle of the high-speed train is characterized in that in the step IV, the length of the fatigue crack along the circumferential direction is also measured.
The test method for the fatigue crack detection capability of the ultrasonic flaw detection on the axle of the high-speed train is characterized in that the test sample axle is a hollow axle.
Compared with the prior art, the invention has the beneficial effects that:
by the test method, the limit detection depth value of the fatigue crack of the axle of the high-speed train by utilizing ultrasonic flaw detection can be accurately known, data support is provided for the regular detection of the axle, and the detection accuracy is improved.
By adopting the test method, the detection capability of the ultrasonic flaw detection on different cracks (different lengths and different depths) at different parts (arc parts and straight sections) of different axles (different axle types and different axle diameters) can be known by using a small number of axles, so that the obtained data has higher rationality and universality.
By adopting the test method, the relation between the length of the fatigue crack and the depth time can be obtained.
The test method also has the advantages of ingenious design and easy realization.
Drawings
FIG. 1 is a schematic flow diagram of the process of the present invention.
FIG. 2 is a schematic illustration of the present invention for machining an artifact in the outer surface of a hollow axle.
Description of reference numerals: A. b, C-location of artificial defect.
Detailed Description
The invention provides a test method for detecting the fatigue crack detection capability of an axle of a high-speed train by ultrasonic flaw detection, which comprises the following steps as shown in figure 1:
preparing a test sample shaft containing fatigue cracks, such as a test sample shaft with a straight section containing the fatigue cracks or a test sample shaft with the fatigue cracks at an arc part;
wherein: the test sample shaft containing the fatigue crack can be obtained by adopting a method of artificially manufacturing the defect and then applying stress to crack and extend the defect;
② fatigue crack exposure: cutting the position of the test sample shaft with the fatigue crack until only the fatigue crack is remained;
thirdly, ultrasonic flaw detection: carrying out flaw detection test on fatigue cracks of the test sample shaft by adopting automatic flaw detection and/or manual flaw detection means and utilizing automatic hollow-axle ultrasonic flaw detection equipment and a hollow-axle flaw detection standard test block, wherein the sensitivity of manual flaw detection and automatic flaw detection is selected according to relevant regulations;
if the fatigue crack can be detected, performing a fourth step, and if the fatigue crack cannot be detected, performing a fifth step;
turning: after measuring the length of the fatigue crack along the circumferential direction, turning the test sample shaft to a certain depth at the fatigue crack position, and returning to the third step;
opening the cross section: and opening the section of the fatigue crack, recording the appearance of the section and measuring the depth and the length of the residual fatigue crack.
The following description of the preferred embodiments of the present invention with reference to the drawings is provided as follows:
preparing a test sample shaft containing fatigue cracks
(1) As shown in fig. 2, the hollow axle with outer surface defect-free EA4T is selected, artificial defects are machined on the outer surface of the hollow axle, and the machining positions, the number and the depth of the artificial defects can be freely selected, such as:
two groups of adjacent artificial defects are arranged at the arc part (namely, the part A) of the hollow axle, and each group of artificial defects comprises two cutting seams (the width is 0.25mm, and the depth is 2.0mm) which are separated by 180 degrees;
a group of artificial defects are respectively arranged at B, C positions of the straight section of the hollow axle, the group of artificial defects corresponding to the B position comprises two cutting seams (the width is 0.25mm, the depth is 3.0mm) which are separated by 180 degrees, and the group of artificial defects corresponding to the C position comprises four cutting seams (the width is 0.25mm, the depth is respectively 0.5mm, 1.0mm, 2.0mm and 3.0mm) which are separated by 90 degrees;
(2) loading 200MPa nominal stress on the cross section of each artificial defect by adopting a full-size wheel axle test bed, so that the two sides of each artificial defect extend and expand to generate fatigue cracks, and the length of one side of each fatigue crack along the circumferential direction is at least 5 mm;
(3) loading 150MPa nominal stress on the fatigue crack to expand the fatigue crack, and stopping loading until the length of one side of the fatigue crack along the circumferential direction is about 10 mm;
② fatigue crack exposure:
turning the hollow axle, removing artificial defects and only remaining fatigue cracks;
thirdly, ultrasonic flaw detection:
the flaw detection method adopts two means of automatic flaw detection and manual flaw detection:
flaw detection equipment and equipment:
(1) automatic hollow axle ultrasonic flaw detection equipment.
(2) And (3) standard test blocks: hollow shaft flaw detection standard test block.
Manual flaw detection sensitivity:
(1)1mm base equivalent sensitivity: the reflected wave height of the 1mm reference defect was manually adjusted to 80%, and the 1mm reference equivalent sensitivity of each probe was recorded.
(2) Reflection gain value of crack: the cracks were identified and the gain was manually adjusted so that the reflected wave from the cracks was as high as 80%, and the gain value was recorded.
Automatic flaw detection sensitivity:
(1) and automatically scanning and detecting fatigue cracks under the sensitivity of a standard equivalent of 1mm, and recording the sensitivity and the crack detection condition.
(2) Under the standard equivalent sensitivity of 1mm, the sensitivity of detecting the artificial defect of the No. 100 total transport of iron (2013) is taken as the automatic scanning detection sensitivity according to the existing process, each crack is scanned, and the sensitivity and the detection condition are recorded.
(3) And under the standard equivalent sensitivity of 1mm, adjusting the gain value, finding out the minimum detection sensitivity for automatically scanning and finding the cracks, and recording each sensitivity.
Turning:
turning the surface of the hollow axle for 1mm each time, then carrying out MT (magnetic powder test) to obtain the length of the fatigue crack, and returning to the step IV to carry out ultrasonic manual flaw detection and/or ultrasonic automatic flaw detection;
note: when the length of the crack along the circumferential direction is less than or equal to 5mm, turning the surface depth of the axle by 0.5mm each time;
the third step and the fourth step are carried out in a circulating way, and the fifth step is carried out until the fatigue crack can not be detected in the third step;
step five: opening the section:
and opening the fatigue crack surface of the axle or cutting a crack section to open the crack surface, observing the fracture, recording the appearance of the fracture and measuring the length and the depth of the residual fatigue crack.
By the test method, the limit detection depth value (namely the depth of the residual fatigue cracks on the end face) of the fatigue cracks of the axle of the high-speed train by utilizing ultrasonic flaw detection can be accurately obtained, data support is provided for the regular detection of the axle, and the detection accuracy is improved.
By adopting the test method, the detection capability of the ultrasonic flaw detection on different cracks (different lengths and different depths) at different parts (arc parts and straight sections) of different axles (different axle types and different axle diameters) can be known by using a small number of axles, so that the obtained data has higher rationality and universality.
By adopting the test method, the relation between the length of the fatigue crack and the depth time can be obtained.
The test method also has the advantages of ingenious design and easy realization.
The foregoing description is intended to be illustrative rather than limiting, and it will be appreciated by those skilled in the art that many modifications, variations or equivalents may be made without departing from the spirit and scope of the invention as defined in the appended claims.
Claims (8)
1. A test method for detecting the fatigue crack detection capability of an axle of a high-speed train by ultrasonic flaw detection is characterized by comprising the following steps:
firstly, preparing a test sample shaft containing fatigue cracks;
wherein, the test sample shaft containing the fatigue crack is obtained by adopting a method of manufacturing artificial defects on the test sample shaft by an artificial manufacturing method, and then applying stress to generate the fatigue crack at the artificial defects and extending
② fatigue crack exposure:
removing artificial defects, and exposing fatigue cracks on the outer surface of the test sample shaft;
thirdly, ultrasonic flaw detection: carrying out flaw detection test on the fatigue crack of the test sample shaft by adopting an automatic flaw detection and/or manual flaw detection means;
if the fatigue crack can be detected, performing a fourth step, and if the fatigue crack cannot be detected, performing a fifth step;
turning: turning the test sample shaft to a certain depth at the fatigue crack position, and returning to the third step;
opening the cross section: the fatigue crack sections were opened and the remaining fatigue crack depths were measured.
2. The method for testing the fatigue crack detection capability of the axle of the high-speed train through ultrasonic flaw detection according to claim 1, wherein in the step II, the artificial defects of the test sample axle are cut to remove the artificial defects until only the fatigue crack is left.
3. The method for testing the fatigue crack detection capability of an axle of a high-speed train through ultrasonic flaw detection according to claim 1, wherein in the step (r), the artificial flaws are arranged at straight sections and/or circular arc positions of the axle of the test sample.
4. The method for testing the fatigue crack detection capability of an axle of a high-speed train by ultrasonic flaw detection according to claim 1 or 3, wherein the artificial flaws are 2, 3, 4 or more cutting seams arranged at circumferential intervals.
5. The method for testing the fatigue crack detection capability of the axle of the high-speed train through ultrasonic flaw detection according to claim 1, wherein in the step (r), a full-size axle test bed is adopted to load nominal stress on the cross section of the artificial defect, so that fatigue cracks are generated and extend on two sides of the artificial defect.
6. The method for testing the fatigue crack detection capability of the axle of the high-speed train through ultrasonic flaw detection according to claim 1, wherein in the step (iii), the fatigue crack of the test sample shaft is subjected to flaw detection by using an automatic hollow axle ultrasonic flaw detection device and a hollow shaft flaw detection standard test block.
7. The method for testing the fatigue crack detecting ability of an axle of a high-speed train by ultrasonic flaw detection according to claim 1, wherein in the step (iv), the length of the fatigue crack in the circumferential direction is also measured.
8. The method of testing the fatigue crack detection capability of an axle of a high-speed train by ultrasonic flaw detection according to claim 1, wherein the test specimen shaft is a hollow axle.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202011601287.5A CN112748188A (en) | 2020-12-29 | 2020-12-29 | Test method for detecting fatigue crack detection capability of axle of high-speed train by ultrasonic flaw detection |
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| CN202011601287.5A CN112748188A (en) | 2020-12-29 | 2020-12-29 | Test method for detecting fatigue crack detection capability of axle of high-speed train by ultrasonic flaw detection |
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Citations (6)
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2020
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Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN101710040A (en) * | 2009-12-10 | 2010-05-19 | 中国航空工业集团公司北京航空材料研究院 | Method for manufacturing surface crack sample for nondestructive testing sensitivity test |
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| CN104820016A (en) * | 2015-04-15 | 2015-08-05 | 南车戚墅堰机车车辆工艺研究所有限公司 | Locomotive connecting shaft fatigue crack ultrasonic detection method |
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