CN112945447A - Magnetic measurement sensing unit, device and method for three-dimensional residual stress field of ferromagnetic component - Google Patents
Magnetic measurement sensing unit, device and method for three-dimensional residual stress field of ferromagnetic component Download PDFInfo
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- CN112945447A CN112945447A CN202110137212.4A CN202110137212A CN112945447A CN 112945447 A CN112945447 A CN 112945447A CN 202110137212 A CN202110137212 A CN 202110137212A CN 112945447 A CN112945447 A CN 112945447A
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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
- G01L5/16—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes for measuring several components of force
- G01L5/169—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes for measuring several components of force using magnetic means
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L1/00—Measuring force or stress, in general
- G01L1/12—Measuring force or stress, in general by measuring variations in the magnetic properties of materials resulting from the application of stress
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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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Abstract
The application belongs to the technical field of sensors, and particularly relates to a magnetic measurement sensing unit, a magnetic measurement sensing device and a magnetic measurement sensing method for a three-dimensional residual stress field of a ferromagnetic component, which aim to solve the problems that the existing residual stress magnetic measurement sensor cannot measure the longitudinal residual stress perpendicular to a structural component and cannot obtain the three-dimensional residual stress field of the ferromagnetic component. The magnetic measurement sensing unit comprises a nine-pole magnetic detection sensor and a transverse magnetic field detection sensor, wherein the nine-pole magnetic detection sensor comprises a nine-pole magnetic core, a first excitation coil, a first detection coil and a second detection coil; the transverse magnetic field detection sensor comprises a U-shaped magnetic core, and a second excitation coil and a third detection coil which are wound on the U-shaped magnetic core. The magnetic measurement sensing unit of the invention directly carries out contact or non-contact measurement on the surface of the ferromagnetic component without any treatment, obtains the three-dimensional residual stress distribution of the point to be measured, and has the advantages of wide application range, quick detection, high efficiency and the like.
Description
Technical Field
The application belongs to the technical field of sensors, and particularly relates to a magnetic measurement sensing unit, a magnetic measurement sensing device and a magnetic measurement sensing method for a three-dimensional residual stress field of a ferromagnetic component.
Background
The residual stress widely exists in the structural parts after casting, welding, heat treatment and the like, can greatly affect the physical and mechanical properties of materials, greatly harm the strength of the structural parts, and seriously affect the quality and safe use of the structural parts. Among the residual stress detection methods, the magnetic detection method can be used for direct detection in a contact or non-contact manner, has high detection speed and high efficiency, and is widely applied.
The existing dipolar, quadrupolar, nine-polar and other residual stress magnetic sensors and devices utilize the linear relation between the relative change amount of the magnetic conductivity and the stress, so that the magnitude of the residual stress can be obtained, and the type and the direction of the residual stress can be rapidly judged. However, the conventional magnetic measuring sensor can only detect the magnitude and direction of the residual stress of a two-dimensional plane, and cannot detect the residual stress in the perpendicular direction in the ferromagnetic component, so that a three-dimensional residual stress field of the ferromagnetic component cannot be obtained, which is disadvantageous for the thicker ferromagnetic component, and may cause fatigue cracks to be generated in the structural component, thereby causing accidents. Therefore, the development of the three-dimensional residual stress magnetic measurement theory and method research of the ferromagnetic component based on the magnetic anisotropy is necessary, and the method has important significance in engineering application.
Disclosure of Invention
Technical problem to be solved
In order to solve the problems that a residual stress magnetic sensor in the prior art cannot measure the longitudinal residual stress perpendicular to a structural member and cannot obtain the three-dimensional residual stress field of a ferromagnetic member, the application provides a magnetic measurement sensing unit, a device and a method for the three-dimensional residual stress field of the ferromagnetic member.
(II) technical scheme
In order to achieve the purpose, the invention adopts the main technical scheme that:
a magnetic measurement sensing unit of a three-dimensional residual stress field of a ferromagnetic component comprises a nine-pole magnetic detection sensor and a transverse magnetic field detection sensor;
the nine-pole magnetic detection sensor comprises a nine-pole magnetic core, a first excitation coil, a first detection coil and a second detection coil; the nine-pole magnetic core consists of a magnetic core end part, 1 excitation column and 8 detection columns, wherein the excitation column is positioned in the center of the magnetic core end part, and the detection columns are uniformly distributed on the circumference with the excitation column as the circle center; the first excitation coil is wound on the excitation column of the nine-pole magnetic core and used for generating a first excitation magnetic field under the action of first excitation current, and the first detection coil and the second detection coil are respectively wound on the 4 detection columns and used for measuring a first induction voltage and a second induction voltage caused by two main stress changes in a vertical direction;
transverse magnetic field detection sensor include U type magnetic core and coiling in the second excitation coil and the third detection coil of U type magnetic core, second excitation coil is used for producing second excitation magnetic field under second exciting current's effect, first exciting current with second exciting current's frequency is the same, the third detection coil is used for measuring the third induced voltage that longitudinal stress arouses.
Optionally, the nine-pole magnetic detection sensor is disposed in a U-shaped groove of the transverse magnetic field detection sensor.
Optionally, the nine-pole magnetic detection sensor comprises a nine-pole magnetic detection sensor housing, and the transverse magnetic field detection sensor comprises a transverse magnetic field detection sensor housing; the nine-pole magnetic detection sensor shell comprises a shell body, a connecting part and a fixing part;
the nine-pole magnetic detection sensor is arranged in the cavity of the shell body;
the fixing part is fixedly connected with the shell of the transverse magnetic field detection sensor;
the connecting part is respectively connected with the shell body and the fixing part, and a cable fixing component is arranged inside the connecting part.
The invention provides a magnetic measuring device for three-dimensional residual stress field of ferromagnetic component in second aspect, which comprises: the magnetic measurement sensing unit of the three-dimensional residual stress field of the ferromagnetic component, the excitation unit, the detection signal processing unit and the residual stress calculation unit;
the excitation unit is respectively connected with a first excitation coil and a second excitation coil of the magnetic measurement sensing unit and is used for generating excitation currents of a nine-pole magnetic detection sensor and a transverse magnetic field detection sensor in the magnetic measurement sensing unit;
the detection signal processing unit is used for amplifying and filtering induced voltage signals output by the nine-pole magnetic detection sensor and the transverse magnetic field detection sensor and sending the processed voltage signals to the residual stress calculation unit;
the residual stress calculation unit is used for receiving the voltage signal output by the detection signal processing unit and calculating the three-dimensional residual stress of each point to be measured based on the voltage signal.
Optionally, the apparatus further comprises:
and the residual stress display unit is used for receiving and displaying the three-dimensional residual stress of each point to be measured output by the residual stress calculation unit.
Optionally, the apparatus further comprises a signal conditioning unit;
the signal adjusting unit is used for adjusting the size and the frequency of the exciting current generated by the exciting unit.
The third aspect of the invention provides a magnetic measurement method for a three-dimensional residual stress field of a ferromagnetic component, which comprises the following steps:
step S10, taking an area needing three-dimensional residual stress detection as a to-be-detected area, determining a to-be-detected plane of the to-be-detected area, and determining a three-dimensional residual stress point set to be detected according to the to-be-detected area and the size of a magnetic measurement sensing unit, wherein the point set to be detected is a uniformly distributed point array, and the number of lines of the point array is an odd number which is more than or equal to 3;
step S20, determining the frequency of the exciting current of the magnetic measurement sensing unit through a skin effect formula based on the depth of the point to be measured in the point set to be measured;
step S30, placing the nine-pole magnetic detection sensor of the magnetic measurement sensing unit at each point to be measured, loading a first exciting current to the nine-pole magnetic detection sensor, and measuring by the nine-pole magnetic detection sensor to obtain a first induced voltage and a second induced voltage of each point to be measured; placing a transverse magnetic field detection sensor of the magnetic measurement sensing unit at each point to be measured, loading a second excitation current on the transverse magnetic field detection sensor to generate a magnetic field with the direction parallel to the detection plane, and measuring by the transverse magnetic field detection sensor to obtain a third induced voltage of each point to be measured;
step S40, obtaining a plane principal stress direction angle and a principal stress difference of each point to be measured according to a predetermined nine-pole magnetic detection sensor calibration coefficient and a first induced voltage and a second induced voltage of each point to be measured; according to a predetermined calibration coefficient of the transverse magnetic field detection sensor and a third induction voltage of each point to be detected, obtaining a maximum value of transverse magnetic flux density and a principal stress sum of a longitudinal surface of each point to be detected;
s50, based on the plane principal stress direction angle and the principal stress difference of each point to be measured, obtaining the plane principal stress and the plane component stress of each point to be measured of even number rows in the point array by a shear stress difference method, wherein the directions of the plane principal stress and the plane component stress are parallel to the plane determined by the point set to be measured;
s60, acquiring the longitudinal partial stress of each to-be-measured point in the even-numbered row in the point array based on the sum of the plane partial stress and the longitudinal plane partial stress of each to-be-measured point;
and step S70, establishing a three-dimensional residual stress field of the ferromagnetic component based on the plane partial stress and the longitudinal partial stress of each point to be measured.
Optionally, the determining the three-dimensional residual stress point set to be measured according to the size of the region to be measured and the size of the magnetic measurement sensing unit includes:
taking the direction perpendicular to the welding seam of the ferromagnetic component as the x direction, and taking the direction parallel to the welding seam of the ferromagnetic component as the y direction;
in the region to be measured, three-dimensional residual stress points to be measured in each line are respectively determined along the x direction, wherein the distance between two adjacent points in the same line and the line distance between adjacent lines are both equal to the diameter of the nine-pole magnetic detection sensor, the projection distance of the points to be measured in the adjacent lines in the x direction is equal to the radius of the nine-pole magnetic detection sensor, and the number of lines is an odd number.
Optionally, the method for determining the calibration coefficient of the transverse magnetic field detection sensor includes:
carrying out a tensile test on the test piece, loading a transverse magnetic field through a transverse magnetic field detection sensor, and measuring induced voltages under different uniaxial stresses;
calculating to obtain the magnetic flux density according to a Faraday electromagnetic induction law;
calculating a calibration coefficient of the transverse magnetic field detection sensor according to a calculation formula of the calibration coefficient of the transverse magnetic field detection sensor, wherein the calculation formula of the calibration coefficient of the transverse magnetic field detection sensor is as follows:
wherein, K1Calibrating the coefficients for the transverse magnetic field detection sensor, BmaxiIs the maximum value of the magnetic flux density, sigma, measured in the ith testiFor uniaxial stress, n is the number of trials.
Optionally, obtaining a maximum value of the transverse magnetic flux density and a sum of principal stresses of the longitudinal surface of each point to be measured according to a predetermined calibration coefficient of the transverse magnetic field detection sensor and a third induced voltage of each point to be measured, including:
s41, measuring through a third detection coil to obtain a third induction voltage;
and S42, calculating to obtain the maximum transverse magnetic flux density according to a magnetic flux density formula based on the obtained third induced voltage, wherein the magnetic flux density formula is as follows:
wherein, BmaxThe maximum value of the transverse magnetic flux density is shown, e represents a third induction voltage, and N represents the number of turns of a third detection coil;
s43, based on the maximum value of the transverse magnetic flux density and the calibration coefficient of the transverse magnetic field detection sensor, calculating to obtain a longitudinal plane main stress sum through a longitudinal plane main stress sum calculation formula, wherein the longitudinal plane main stress sum calculation formula is as follows:
Bmax＝K1(σy+σz)
wherein, K1Representing the calibration coefficient of the transverse magnetic field detection sensor, BmaxRepresents the maximum value of transverse magnetic flux density, σy+σzThe sum of the longitudinal plane principal stresses is indicated.
(III) advantageous effects
The invention has the beneficial effects that: the magnetic measurement sensing unit comprises a nine-pole magnetic detection sensor and a transverse magnetic field detection sensor, wherein the nine-pole magnetic detection sensor comprises a nine-pole magnetic core, a first excitation coil, a first detection coil and a second detection coil; the transverse magnetic field detection sensor comprises a U-shaped magnetic core, and a second excitation coil and a third detection coil which are wound on the U-shaped magnetic core. The magnetic measurement sensing unit of the invention directly carries out contact or non-contact measurement on the surface of the ferromagnetic component without any treatment, thereby obtaining the three-dimensional residual stress distribution of the point to be measured.
Further, by adopting the three-dimensional residual stress field magnetic measurement device and method for the ferromagnetic component of the magnetic measurement sensing unit, a nine-pole magnetic detection sensor is adopted to obtain a plane main stress difference and a main stress direction angle, and then a shear stress difference method is adopted to obtain a plane main stress and a partial stress of each point to be measured; meanwhile, the transverse magnetic field detection sensor is adopted to obtain the longitudinal surface partial stress sum, so that the three-dimensional residual stress of the point to be detected can be further obtained, and the method has the advantages of wide application range, high detection speed, high efficiency and the like.
Drawings
The invention is described with the aid of the following figures:
FIG. 1 is a schematic diagram of a magnetic measurement sensing unit according to an embodiment of the present application;
FIG. 2 is a schematic view of a nine-pole magnetic core structure in one embodiment of the present application;
FIG. 3 is a cross-sectional view of a nine-pole magnetic sensing sensor housing in one embodiment of the present application;
FIG. 4 is a schematic structural diagram of a transverse magnetic field sensor housing in an embodiment of the present application;
FIG. 5 is a block diagram of a magnetic measurement device for three-dimensional residual stress field of a ferromagnetic component in another embodiment of the present application;
FIG. 6 is a flow chart of a magnetic measurement method for a three-dimensional residual stress field of a ferromagnetic component according to yet another embodiment of the present application;
FIG. 7 is a schematic diagram illustrating selection of a three-dimensional set of points to be measured for residual stress in yet another embodiment of the present application;
FIG. 8 is a schematic diagram illustrating a three-dimensional residual stress field in a weld zone according to yet another embodiment of the present application.
[ description of reference ]
10-nine-pole magnetic detection sensor, 11-first detection coil, 12-second detection coil, 13-nine-pole magnetic core, 14-first excitation coil;
20-a transverse magnetic field detection sensor, 21-a second excitation coil, 22-a third detection coil and 23-a U-shaped magnetic core;
130-magnetic core end, 131-detection column one, 132-detection column two, 133-detection column three, 134-detection column four, 135-detection column five, 136-detection column six, 137-detection column seven, 138-detection column eight, 139-excitation column;
31-a fixed part of a shell of the nine-pole magnetic detection sensor, 32-a connecting part of the shell of the nine-pole magnetic detection sensor, 33-a shell body of the nine-pole magnetic detection sensor, 311-a groove, 321-a wiring groove, 322-a thread and 331-a cavity of the nine-pole sensor;
401-left side of a shell of a transverse magnetic field detection sensor, 402-right side of the shell of the transverse magnetic field detection sensor, 411-fixed female buckle, 412-fixed male buckle, 42-cavity of the shell of the transverse magnetic field detection sensor, 431-left side of a hoop and 432-right side of the hoop;
71-ferromagnetic steel plate, 72-steel plate welding line, 73-steel plate residual stress region to be measured, 74-residual stress point to be measured in the steel plate region to be measured, 75-ferromagnetic pipeline, 76-pipeline welding line, 77-pipeline residual stress region to be measured, and 78-residual stress point to be measured in the pipeline region to be measured.
Detailed Description
For the purpose of better explaining the present invention and to facilitate understanding, the present invention will be described in detail by way of specific embodiments with reference to the accompanying drawings. It is to be understood that the embodiments described are only a few embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The terms "first," "second," and the like are used for distinguishing between similar elements and not necessarily for describing or implying a particular order or sequence.
For a better understanding of the present invention, the principle of the residual stress detection is explained below, and then the present invention is described.
The ferromagnetic material and the ferrimagnetic material have small changes in material dimensions due to changes in magnetization states, which is a magnetostrictive effect. On the contrary, under the action of external force such as pulling force, pressure, torsion force and the like, the magnetic domain structure in the ferromagnetic material changes, so that the magnetic characteristics change correspondingly, and the phenomenon is the inverse magnetostriction effect. Under the effect of inverse magnetostriction, the material generates magnetic anisotropy, i.e. a change in stress or strain state will cause a change in the permeability or reluctance of the ferromagnetic material. Under the condition that the magnetic sensor provides constant magnetomotive force, the change of magnetic resistance in the magnetic circuit causes the change of magnetic flux, and the change of magnetic flux causes the change of the induced electromotive force of a detection coil of the sensor. Therefore, the non-electrical stress strain is converted into measurable voltage, and the purpose of residual stress detection is achieved.
The invention utilizes the characteristics of ferromagnetic materials: the magnetic anisotropy is expressed when no stress exists, the magnetic anisotropy is expressed when the stress exists, and a linear relation exists between the relative change quantity of the magnetic conductivity and the stress; the magnetic measurement sensing unit, the device and the method for the three-dimensional residual stress field of the ferromagnetic component are provided, so that the limitation that the residual stress of a two-dimensional plane can only be detected in the prior art is overcome, and the problem of detecting the longitudinal residual stress in the structural component is solved.
Example one
Fig. 1 is a schematic structural diagram of a magnetic measurement sensing unit in an embodiment of the present application, and as shown in fig. 1, the magnetic measurement sensing unit for a three-dimensional residual stress field of a ferromagnetic component in the embodiment includes: a nine-pole magnetic detection sensor and a transverse magnetic field detection sensor;
the nine-pole magnetic detection sensor comprises a nine-pole magnetic core 13, a first excitation coil, a first detection coil 11 and a second detection coil 12; the nine-pole magnetic core consists of a magnetic core end part, 1 excitation column and 8 detection columns, wherein the excitation column is positioned in the center of the magnetic core end part, and the detection columns are uniformly distributed on the circumference with the excitation column as the circle center; the first excitation coil is wound on an excitation column of the nine-pole magnetic core and used for generating a first excitation magnetic field under the action of first excitation current, and the first detection coil and the second detection coil are respectively wound on the 4 detection columns and used for measuring a first induction voltage and a second induction voltage caused by two main stress changes in a vertical direction;
the transverse magnetic field detection sensor comprises a U-shaped magnetic core 23, a second excitation coil 21 and a third detection coil 22, wherein the second excitation coil 21 is wound on the U-shaped magnetic core and used for generating a second excitation magnetic field under the action of second excitation current, the frequency of the first excitation current is the same as that of the second excitation current, and the third detection coil 22 is used for measuring third induced voltage caused by longitudinal stress.
The magnetic measurement sensing unit of the invention directly carries out contact or non-contact measurement on the surface of the ferromagnetic component without any treatment, thereby obtaining the three-dimensional residual stress distribution of the point to be measured.
The following specifically describes the structures of the nine-pole magnetic detection sensor and the transverse magnetic field detection sensor in the present embodiment.
Referring to fig. 2, fig. 2 is a schematic structural diagram of a nine-pole magnetic core according to an embodiment of the present application; in fig. 2, (a) is a bottom view of the nine-pole core, and (b) is a side view of the nine-pole core.
The nine-pole magnetic detection sensor includes a nine-pole magnetic core 13, a first excitation coil, a first detection coil 11, and a second detection coil 12. As shown in fig. 2, the nine-pole magnetic core 13 is composed of a magnetic core end 130, 1 excitation column 139 and 8 detection columns, namely, a first detection column 131, a second detection column 132, a third detection column 133, a fourth detection column 134, a fifth detection column 135, a sixth detection column 136, a seventh detection column 137 and an eighth detection column 138, wherein the middle pole of the magnetic core is used as the excitation column 139 for winding the first excitation coil, and the first detection column 131, the second detection column 132, the third detection column 133, the fourth detection column 134, the fifth detection column 135, the sixth detection column 136, the seventh detection column 137 and the eighth detection column 138 are used for winding the first detection coil 11 and the second detection coil 12; the coils wound on the first detection column 131, the third detection column 133, the fifth detection column 135 and the seventh detection column 137 are used as the first detection coil 11 and are in differential connection, namely, the coils on the first detection column 131 and the fifth detection column 135 are wound in the same direction and then wound in opposite directions on the third detection column 133 and the seventh detection column 137; the coils wound on the second detection column 132, the fourth detection column 134, the sixth detection column 136 and the eighth detection column 138 are used as a second detection coil 12 and are in differential connection, namely the coils on the second detection column 132 and the sixth detection column 136 are wound in the same direction and then wound in opposite directions; and respectively forming an induced voltage output stage, and outputting to obtain a first induced voltage and a second induced voltage. The nine-pole magnetic sensor is arranged at a measuring point position and used for collecting magnetic signals caused by residual stress; nine magnetic cores of the magnetic cores are mutually symmetrical, and every two adjacent poles are different by 45 degrees. Nine poles are connected into a whole through magnetic core tip 19, and the magnetic core tip is circular, can reduce the magnetic leakage. The magnetic core material needs to be a soft magnetic material with high magnetic conductivity and high saturation magnetic flux density, and the number of winding turns of each detection coil needs to be the same.
The lateral magnetic field detection sensor is composed of a U-shaped magnetic core 23, a second excitation coil 21 for generating an excitation field, and a third detection coil 22 for detecting an induced voltage. The frequency of the exciting current on the second exciting coil 21 is the same as that on the first exciting coil.
In some embodiments, the nine-pole magnetic sensing sensor further comprises a housing for holding the nine-pole magnetic sensing sensor. Fig. 3 is a cross-sectional view of a nine-pole magnetic sensor housing according to an embodiment of the present application, as shown in fig. 3, the nine-pole magnetic sensor housing includes: the fixing part 31, the connecting part 32 and the shell body 33, the fixing part 31 is provided with a groove 311 which can be used for fixing the U-shaped magnetic core 23 of the transverse magnetic field detection sensor; the connecting part 32 passes through a thread 322, the bolt fixing part 31 and the shell body 33, and the thread 322 is provided with a wiring groove 321 for fixing wiring; the lower section has a nine-pole sensor cavity 331 for securing and protecting a nine-pole magnetic sensing sensor.
In some embodiments, the transverse magnetic field detection sensor further comprises a housing for protecting the transverse magnetic field detection sensor. Fig. 4 is a schematic structural diagram of a housing of a transverse magnetic field detection sensor according to an embodiment of the present application, where (a) in fig. 4 is a schematic structural diagram of a housing of a transverse magnetic field detection sensor with a female buckle side, and (b) is a schematic structural diagram of a housing of a transverse magnetic field detection sensor with a male buckle side. As shown in fig. 4, the transverse magnetic field detection sensor housing is composed of two symmetrical parts, namely a left transverse magnetic field detection sensor housing 401, a right transverse magnetic field detection sensor housing 402, a left housing 401 with a female fastening button 411, and a right housing 402 with a male fastening button 412. When the transverse magnetic field detection sensor is used, the transverse magnetic field detection sensor is placed in the cavity 42 of the left shell 401, the right shell 402 is buckled, the male buckle 412 is aligned with the female buckle 411, the transverse magnetic field detection sensor is pressed downwards, and the transverse magnetic field detection sensor is fixed. The clamp left 431 and the clamp right 432 are fixed on the shell of the transverse magnetic field detection sensor, and the transverse magnetic field detection sensor is fixed at the groove of the shell of the nine-pole magnetic detection sensor by rotating screws on two sides of the clamp, so that the two sensors are combined into one sensor, and the three-dimensional residual stress magnetic detection sensor with the protective shell is formed.
The shell of the three-dimensional residual stress magnetic sensor can effectively fix and protect the three-dimensional residual stress magnetic sensor.
Example two
The second aspect of the present application proposes a magnetic measurement device for a three-dimensional residual stress field of a ferromagnetic component, the device comprising: the magnetic measurement sensing unit of the three-dimensional residual stress field of the ferromagnetic component, the excitation unit, the detection signal processing unit and the residual stress calculation unit;
the excitation unit is respectively connected with a first excitation coil and a second excitation coil of the magnetic measurement sensing unit and is used for generating excitation currents of a nine-pole magnetic detection sensor and a transverse magnetic field detection sensor in the magnetic measurement sensing unit;
the detection signal processing unit is used for amplifying and filtering induced voltage signals output by the nine-pole magnetic detection sensor and the transverse magnetic field detection sensor and sending the processed voltage signals to the residual stress calculation unit;
and the residual stress calculation unit is used for receiving the voltage signal output by the detection signal processing unit and calculating the three-dimensional residual stress of each point to be measured based on the voltage signal.
In order to better understand the magnetic measurement device for the three-dimensional residual stress field of the ferromagnetic component in the present application, an embodiment is provided below, which is specifically described.
Fig. 5 is a block diagram of a magnetic measurement device for a three-dimensional residual stress field of a ferromagnetic member according to another embodiment of the present application, and as shown in fig. 5, the magnetic measurement device for a three-dimensional residual stress field of a ferromagnetic member includes:
the three-dimensional residual stress magnetic measurement sensing unit is used for measuring the residual stress of a region to be measured and comprises a nine-pole magnetic detection sensor and a transverse magnetic field detection sensor. The nine-pole magnetic detection sensor is used for generating an excitation magnetic field and acquiring an induced voltage signal. The nine-pole magnetic sensor further includes: the magnetic core is integrally processed and comprises an excitation column and eight detection columns which are used for winding the excitation coil and the detection coil; and the transverse magnetic field detection sensor is used for loading a transverse excitation magnetic field and acquiring an induced voltage signal of the detection coil.
The magnetic sensor shell is used for fixing the three-dimensional residual stress magnetic sensor and comprises a nine-pole magnetic sensor shell for fixing the nine-pole magnetic sensor and a transverse magnetic field detection sensor shell for protecting the transverse magnetic field detection sensor.
An exciting device for generating exciting currents of the nine-pole magnetic detection sensor and the transverse magnetic field detection sensor;
the detection signal processing device is used for amplifying and filtering induced voltage signals detected by the nine-pole magnetic sensor and the transverse magnetic field detection sensor;
and the residual stress display device is used for calculating and displaying the processed detection signal, and comprises calculation and display of two-dimensional residual stress and calculation and display of longitudinal residual stress.
The residual stress display device further includes: (1) and calculating and displaying the two-dimensional plane residual stress. Calculating the main stress difference (sigma) of the measuring point according to the induction voltage data acquired by the nine-pole magnetic sensor1-σ2) And the maximum stress direction angle theta is summed, and then the shear stress difference is separated by utilizing a shear stress difference method to obtain the main stress sigma of the measuring point1、σ2And component stress σx、σyAnd displaying; (2) and calculating and displaying the longitudinal residual stress. Calculating to obtain a maximum magnetic flux density value B according to the induced voltage data acquired by the transverse magnetic field loadermaxFurther, the partial stress sum (sigma) of the measuring points is obtainedx+σz) Simultaneous equations to obtain the magnitude of longitudinal component stress sigmazAnd displaying.
The magnetic measurement device for the three-dimensional residual stress field of the ferromagnetic component in the embodiment can accurately measure the three-dimensional residual stress of the ferromagnetic component, can display the three-dimensional residual stress through the detection signal processing device and the residual stress display device, can clearly display the residual stress distribution of a measured point, and has the advantages of high detection speed, high efficiency, no need of surface treatment, wide application range and obvious application advantages.
EXAMPLE III
The third aspect of the application provides a magnetic measurement method for a three-dimensional residual stress field of a ferromagnetic component. Fig. 6 is a flow chart of a magnetic measurement method of a three-dimensional residual stress field of a ferromagnetic component according to still another embodiment of the present application, and the method in this embodiment is described in detail below with reference to fig. 6.
Step S10, taking the area needing three-dimensional residual stress detection as the area to be detected, determining the plane to be detected of the area to be detected, and determining a three-dimensional residual stress point set to be detected according to the area to be detected and the size of the magnetic measurement sensing unit, wherein the point set to be detected is a uniformly distributed point array, and the number of lines of the point array is an odd number which is more than or equal to 3.
Fig. 7 is a schematic diagram of selecting a three-dimensional residual stress point set to be measured in yet another embodiment of the present application, where (a) in fig. 7 is a schematic diagram of selecting a three-dimensional residual stress point set to be measured in a ferromagnetic steel plate weld area, and (b) in fig. 7 is a schematic diagram of selecting a three-dimensional residual stress point set to be measured in a ferromagnetic pipeline weld area, as shown in fig. 7, surfaces of a ferromagnetic steel plate 71 and a ferromagnetic pipeline 75 are taken as two-dimensional planes to be measured, and an x direction may be any direction, because a maximum stress direction angle obtained by detection is related to the x direction, for better marking, a direction of the ferromagnetic steel plate perpendicular to a steel plate weld 72, a direction of a pipeline weld 76 is an x direction. And respectively determining a steel plate residual stress region to be measured 73 and a pipeline residual stress region to be measured 77, wherein a residual stress point to be measured 74 in the steel plate region to be measured and a residual stress point to be measured 78 in the pipeline region to be measured are projections of points to be measured in the welding line region of the ferromagnetic steel plate 71 and the ferromagnetic pipeline 75 on a plane to be measured, wherein i represents a line number, j represents a column number, and d represents the distance between two measuring points in the same line.
The method for determining the residual stress point to be measured 74 in the area to be measured of the steel plate and the residual stress point to be measured 78 in the area to be measured of the pipeline comprises the following steps:
and determining the position of the point to be measured from left to right and from top to bottom in the area to be measured along the x direction and the-y direction. Firstly, determining the position of a measurement starting point (1, 1), then marking the measurement points (1, 2) at intervals of d (the diameter of the sensor), marking the measurement points (1, 3), (1, 4) and … … (1, j) in sequence, and finishing marking of a first line measurement point;
and determining the measuring points of the second row, wherein the points (2, 1) are staggered by a distance of d/2 in the x direction, namely, the distance of d is vertically downward from the middle of (1, 1) and (1, 2). Sequentially marking points to obtain the positions of the points (2, 2) - (2, j) when the distance is unchanged;
and determining measuring points of a third row and a fourth row. At the distance of 2d, aligning the point (3, 1) with the point (1, 1), aligning the point (4, 1) with the point (2, 1), and sequentially marking out a third row of measuring points and a fourth row of measuring points;
and sequentially marking points according to the method to obtain a point set to be detected and the total row number.
Thus, the stress is decomposed by the shear stress difference method, and the magnitude and direction of the stress in the even-numbered rows can be obtained finally.
And step S20, determining the frequency of the exciting current of the magnetic measurement sensing unit through a skin effect formula based on the depth of the point to be measured in the point set to be measured.
In this embodiment, according to the depth of the point to be measured, the frequency of the excitation current is determined by the ferromagnetic material skin effect formula shown in formula (1).
Wherein: d is the reconstruction depth, f is the excitation current frequency, μ is the magnetic permeability, and σ is the electrical conductivity. The excitation current includes excitation currents of the nine-pole magnetic detection sensor and the transverse magnetic field detection sensor.
Step S30, placing the nine-pole magnetic detection sensor of the magnetic measurement sensing unit at each point to be measured, loading a first exciting current to the nine-pole magnetic detection sensor, and measuring by the nine-pole magnetic detection sensor to obtain a first induced voltage and a second induced voltage of each point to be measured; and arranging a transverse magnetic field detection sensor of the magnetic measurement sensing unit at each point to be measured, loading a second exciting current to the transverse magnetic field detection sensor to generate a magnetic field with the direction parallel to the detection plane, and measuring by the transverse magnetic field detection sensor to obtain a third induced voltage of each point to be measured.
In this embodiment, the nine-pole magnetic sensor and the transverse magnetic field loader are simultaneously placed at each point to be measured. Fig. 8 is a schematic diagram illustrating the detection of the three-dimensional residual stress field in the weld zone according to yet another embodiment of the present application, and as shown in fig. 8, a connection line between the excitation pillar and the first detection pillar of the nine-pole magnetic detection sensor 10 points in a direction consistent with the X direction. Wherein, the direction of X is perpendicular to the steel plate welding seam 72 on the ferromagnetic steel plate 71 to be measured.
First, an exciting current is loaded on a first exciting coil 14 of the nine-pole magnetic detection sensor 10 to generate a magnetic field B', and points to be measured are measured through a first detection coil 11 and a second detection coil 12 of the nine-pole magnetic detection sensor to obtain a corresponding first induced voltage and a corresponding second induced voltage, wherein the first induced voltage and the second induced voltage are induced voltages caused by main stress changes in two directions perpendicular to each other.
The x-direction magnetic field B is generated by applying an excitation current to the second excitation coil 21 of the lateral magnetic field detection sensor 20, and the induced voltage at the third detection coil 22 is measured.
Step S40, obtaining a plane principal stress direction angle and a principal stress difference of each point to be measured according to a predetermined nine-pole magnetic detection sensor calibration coefficient and a first induced voltage and a second induced voltage of each point to be measured; and obtaining the maximum value of the transverse magnetic flux density and the sum of the longitudinal surface principal stress of each point to be measured according to the predetermined calibration coefficient of the transverse magnetic field detection sensor and the third induced voltage of each point to be measured.
When determining the calibration coefficient, firstly determining the parameters of the material, the size, the depth, the thickness of the anticorrosive layer and the like of the region to be measured, manufacturing a test piece according to the parameters of the material of the ferromagnetic component, the thickness of the anticorrosive layer and the like, and then determining the corresponding calibration coefficient through a tensile test.
The method for acquiring the calibration coefficient of the transverse magnetic field detection sensor comprises the following steps:
s401, performing a tensile test on a test piece, loading a transverse magnetic field through a transverse magnetic field detection sensor, and measuring induced voltages e under the action of different uniaxial stresses;
s402, calculating by the formula (3) according to a Faraday electromagnetic induction law shown in the formula (2) to obtain a magnetic flux density;
wherein, BmaxRepresents the maximum value of the transverse magnetic flux density, e represents the third induced voltage,n denotes the number of third detection coil turns.
And S403, calculating according to a calibration coefficient calculation formula shown in the formula (4) to obtain a calibration coefficient.
Wherein, K1Calibrating the coefficients for the transverse magnetic field detection sensor, BmaxiIs the maximum value of the magnetic flux density, sigma, measured in the ith testiFor uniaxial stress, n is the number of trials.
Wherein the maximum value B of the magnetic flux density measured in the ith test is determinedmaxiThe method comprises the following steps: the measured point of the ferromagnetic component is magnetized to a near saturation or saturation state by loading large current, and the magnetic flux density value at the moment is the maximum value B of the magnetic flux densitymaxi。
The method for determining the calibration coefficient of the nine-pole magnetic detection sensor comprises the following steps:
s411, performing a tensile test on the test piece, loading a magnetic field through a nine-pole magnetic detection sensor, and measuring a first induced voltage and a second induced voltage under different uniaxial stresses;
s412, calculating according to the formula (5) to obtain stress voltage;
wherein V is the stress voltage, V0Seventhly, a first induction voltage V output by a detection coil wound on the column45A second induction voltage output by the detection coil wound on the ((r));
and S403, calculating according to a calibration coefficient calculation formula shown in the formula (6) to obtain a calibration coefficient.
Wherein, K2For nine-pole magnetic detection sensor calibration coefficient, VjFor the stress voltage, σ, obtained in the jth loading testjThe uniaxial stress in the jth loading test is shown, and m is the number of tests.
According to the predetermined calibration coefficient of the nine-pole magnetic detection sensor and the first induced voltage V of each point to be measured0And a second induced voltage V45Calculating the main stress difference (sigma) of each point to be measured by the formulas (7) and (8)1-σ2) And a principal stress direction angle theta.
Wherein σ1Is the first principal stress, σ2Is the second principal stress, K2Is a calibration coefficient, V, of a nine-pole magnetic detection sensor0Is a first induced voltage, V45Is the second induced voltage.
Wherein, theta is the principal stress direction angle, V0Is a first induced voltage, V45Is the second induced voltage.
Calculating to obtain a maximum magnetic flux density value B according to a predetermined calibration coefficient of the transverse magnetic field detection sensor and a third induction voltage of each point to be measuredmax。
Due to longitudinal plane component stress sum sigmay+σzIs related to the magnetic flux density B and has a linear relationship as shown in formula (9):
Bmax＝K1(σy+σz) (9)
wherein, K1Representing the calibration coefficient of the transverse magnetic field detection sensor, BmaxRepresents the maximum value of the magnetic flux density;
therefore, after the maximum value of the magnetic flux density is obtained, the coefficient K is calibrated1The longitudinal surface partial stress sum σ can be further calculated and obtained by equation (9)y+σz。
And S50, obtaining the plane principal stress and the plane component stress of each point to be measured in the even number of rows in the point array by adopting a shear stress difference method based on the plane principal stress direction angle and the principal stress difference of each point to be measured, wherein the direction of the plane principal stress and the plane component stress is parallel to the plane determined by the point set to be measured.
Referring to FIG. 8, the principal stress σ is obtained by decomposition using the shear stress difference method1、σ2And the partial stress sigma of the point to be measuredx、σyIn this embodiment, the directions of the plane component stresses are the x direction and the y direction.
And S60, acquiring the longitudinal partial stress of each to-be-measured point in the even-numbered row in the point array based on the sum of the plane partial stress and the longitudinal plane partial stress of each to-be-measured point.
The longitudinal surface partial stress sum sigma of the yz plane of the point to be measured is obtained by calculationy+σzMiddle substituted plane partial stress value sigmayThe longitudinal component stress sigma can be obtainedzSize.
And step S70, establishing a three-dimensional residual stress field of the ferromagnetic component based on the plane partial stress and the longitudinal partial stress of each point to be measured.
In this embodiment, a three-dimensional residual stress field of the weld detection area is established, specifically, the linear segments are generated in a software manner to respectively describe the component stress σx、σyAnd σzThe length of the straight line segment indicates the magnitude of the partial stress, and the partial stress sigma of all points to be measured is displayed by utilizing the straight line segmentx、σyAnd σzThe three-dimensional residual stress distribution field of the region to be measured is obtained.
The method belongs to a magnetic detection method, is a new method capable of detecting the three-dimensional residual stress field of the ferromagnetic component, has high detection speed and high detection efficiency, is beneficial to evaluating the quality of the ferromagnetic component and the operation condition of industrial equipment, can prevent accidents and generates great economic benefit and social benefit.
As a further optimization scheme of the magnetic measurement method for the three-dimensional residual stress field of the ferromagnetic component in this embodiment, three-dimensional residual stress calculation models at different thicknesses of the ferromagnetic component can be obtained by selecting different excitation frequencies according to a skin effect formula of the ferromagnetic material.
It can be clearly understood by those skilled in the art that, for convenience and brevity of description, the specific working process and related descriptions of the above-described apparatus may refer to the corresponding process in the foregoing method embodiments, and are not described herein again.
It should be understood that the above description of specific embodiments of the present invention is only for the purpose of illustrating the technical lines and features of the present invention, and is intended to enable those skilled in the art to understand the contents of the present invention and to implement the present invention, but the present invention is not limited to the above specific embodiments. It is intended that all such changes and modifications as fall within the scope of the appended claims be embraced therein.
Claims (10)
1. A magnetic measurement sensing unit of a three-dimensional residual stress field of a ferromagnetic component is characterized in that the magnetic measurement sensing unit comprises a nine-pole magnetic detection sensor and a transverse magnetic field detection sensor;
the nine-pole magnetic detection sensor comprises a nine-pole magnetic core, a first excitation coil, a first detection coil and a second detection coil; the nine-pole magnetic core consists of a magnetic core end part, 1 excitation column and 8 detection columns, wherein the excitation column is positioned in the center of the magnetic core end part, and the detection columns are uniformly distributed on the circumference with the excitation column as the circle center; the first excitation coil is wound on the excitation column of the nine-pole magnetic core and used for generating a first excitation magnetic field under the action of first excitation current, and the first detection coil and the second detection coil are respectively wound on the 4 detection columns and used for measuring a first induction voltage and a second induction voltage caused by two main stress changes in a vertical direction;
transverse magnetic field detection sensor include U type magnetic core and coiling in the second excitation coil and the third detection coil of U type magnetic core, second excitation coil is used for producing second excitation magnetic field under second exciting current's effect, first exciting current with second exciting current's frequency is the same, the third detection coil is used for measuring the third induced voltage that longitudinal stress arouses.
2. The magnetic measurement sensing unit of three-dimensional residual stress field of ferromagnetic component according to claim 1, characterized in that said nine-pole magnetic detection sensor is arranged in a U-shaped slot of said transverse magnetic field detection sensor.
3. The magnetic measurement sensing unit of three-dimensional residual stress field of ferromagnetic component of claim 2, characterized in that said nine-pole magnetic detection sensor comprises a nine-pole magnetic detection sensor housing, said transverse magnetic field detection sensor comprises a transverse magnetic field detection sensor housing; the nine-pole magnetic detection sensor shell comprises a shell body, a connecting part and a fixing part;
the nine-pole magnetic detection sensor is arranged in the cavity of the shell body;
the fixing part is fixedly connected with the shell of the transverse magnetic field detection sensor;
the connecting part is respectively connected with the shell body and the fixing part, and a cable fixing component is arranged inside the connecting part.
4. A magnetic measuring device for a three-dimensional residual stress field of a ferromagnetic component, the device comprising: a magnetic measurement sensing unit of the three-dimensional residual stress field of the ferromagnetic component as set forth in any one of claims 1 to 3, and an excitation unit, a detection signal processing unit and a residual stress calculation unit;
the excitation unit is respectively connected with a first excitation coil and a second excitation coil of the magnetic measurement sensing unit and is used for generating excitation currents of a nine-pole magnetic detection sensor and a transverse magnetic field detection sensor in the magnetic measurement sensing unit;
the detection signal processing unit is used for amplifying and filtering induced voltage signals output by the nine-pole magnetic detection sensor and the transverse magnetic field detection sensor and sending the processed voltage signals to the residual stress calculation unit;
the residual stress calculation unit is used for receiving the voltage signal output by the detection signal processing unit and calculating the three-dimensional residual stress of each point to be measured based on the voltage signal.
5. A magnetic measuring device of a three-dimensional residual stress field of a ferromagnetic component as recited in claim 4, characterized in that the device further comprises:
and the residual stress display unit is used for receiving and displaying the three-dimensional residual stress of each point to be measured output by the residual stress calculation unit.
6. A magnetic measuring device of a three-dimensional residual stress field of a ferromagnetic component as recited in claim 5, characterized in that the device further comprises a signal conditioning unit;
the signal adjusting unit is used for adjusting the size and the frequency of the exciting current generated by the exciting unit.
7. A magnetic measurement method for three-dimensional residual stress field of ferromagnetic component is characterized in that the method comprises:
step S10, taking an area needing three-dimensional residual stress detection as a to-be-detected area, determining a to-be-detected plane of the to-be-detected area, and determining a three-dimensional residual stress point set to be detected according to the to-be-detected area and the size of a magnetic measurement sensing unit, wherein the point set to be detected is a uniformly distributed point array, and the number of lines of the point array is an odd number which is more than or equal to 3;
step S20, determining the frequency of the exciting current of the magnetic measurement sensing unit through a skin effect formula based on the depth of the point to be measured in the point set to be measured;
step S30, placing the nine-pole magnetic detection sensor of the magnetic measurement sensing unit at each point to be measured, loading a first exciting current to the nine-pole magnetic detection sensor, and measuring by the nine-pole magnetic detection sensor to obtain a first induced voltage and a second induced voltage of each point to be measured; placing a transverse magnetic field detection sensor of the magnetic measurement sensing unit at each point to be measured, loading a second excitation current on the transverse magnetic field detection sensor to generate a magnetic field with the direction parallel to the detection plane, and measuring by the transverse magnetic field detection sensor to obtain a third induced voltage of each point to be measured;
step S40, obtaining a plane principal stress direction angle and a principal stress difference of each point to be measured according to a predetermined nine-pole magnetic detection sensor calibration coefficient and a first induced voltage and a second induced voltage of each point to be measured; according to a predetermined calibration coefficient of the transverse magnetic field detection sensor and a third induction voltage of each point to be detected, obtaining a maximum value of transverse magnetic flux density and a principal stress sum of a longitudinal surface of each point to be detected;
s50, based on the plane principal stress direction angle and the principal stress difference of each point to be measured, obtaining the plane principal stress and the plane component stress of each point to be measured of even number rows in the point array by a shear stress difference method, wherein the directions of the plane principal stress and the plane component stress are parallel to the plane determined by the point set to be measured;
s60, acquiring the longitudinal partial stress of each to-be-measured point in the even-numbered row in the point array based on the sum of the plane partial stress and the longitudinal plane partial stress of each to-be-measured point;
and step S70, establishing a three-dimensional residual stress field of the ferromagnetic component based on the plane partial stress and the longitudinal partial stress of each point to be measured.
8. The magnetic measurement method of the three-dimensional residual stress field of the ferromagnetic member according to claim 7, wherein determining the set of three-dimensional residual stress points to be measured according to the dimensions of the region to be measured and the magnetic measurement sensing unit comprises:
taking the direction perpendicular to the welding seam of the ferromagnetic component as the x direction, and taking the direction parallel to the welding seam of the ferromagnetic component as the y direction;
in the region to be measured, three-dimensional residual stress points to be measured in each line are respectively determined along the x direction, wherein the distance between two adjacent points in the same line and the line distance between adjacent lines are both equal to the diameter of the nine-pole magnetic detection sensor, the projection distance of the points to be measured in the adjacent lines in the x direction is equal to the radius of the nine-pole magnetic detection sensor, and the number of lines is an odd number.
9. The magnetic measurement method of the three-dimensional residual stress field of the ferromagnetic component according to claim 7, wherein the determination method of the calibration coefficient of the transverse magnetic field detection sensor is as follows:
carrying out a tensile test on the test piece, loading a transverse magnetic field through a transverse magnetic field detection sensor, and measuring induced voltages under different uniaxial stresses;
calculating to obtain the magnetic flux density according to a Faraday electromagnetic induction law;
calculating a calibration coefficient of the transverse magnetic field detection sensor according to a calculation formula of the calibration coefficient of the transverse magnetic field detection sensor, wherein the calculation formula of the calibration coefficient of the transverse magnetic field detection sensor is as follows:
wherein, K1Calibrating the coefficients for the transverse magnetic field detection sensor, BmaxiIs the maximum value of the magnetic flux density, sigma, measured in the ith testiFor uniaxial stress, n is the number of trials.
10. The magnetic measurement method of the three-dimensional residual stress field of the ferromagnetic component according to claim 7, wherein the step of obtaining the maximum value of the transverse magnetic flux density and the sum of the principal stress of the longitudinal surface of each point to be measured according to the predetermined calibration coefficient of the transverse magnetic field detection sensor and the third induced voltage of each point to be measured comprises the following steps:
s41, measuring through a third detection coil to obtain a third induction voltage;
and S42, calculating to obtain the maximum transverse magnetic flux density according to a magnetic flux density formula based on the obtained third induced voltage, wherein the magnetic flux density formula is as follows:
wherein, BmaxThe maximum value of the transverse magnetic flux density is shown, e represents a third induction voltage, and N represents the number of turns of a third detection coil;
s43, based on the maximum value of the transverse magnetic flux density and the calibration coefficient of the transverse magnetic field detection sensor, calculating to obtain a longitudinal plane main stress sum through a longitudinal plane main stress sum calculation formula, wherein the longitudinal plane main stress sum calculation formula is as follows:
Bmax＝K1(σy+σz)
wherein, K1Representing the calibration coefficient of the transverse magnetic field detection sensor, BmaxRepresents the maximum value of transverse magnetic flux density, σy+σzThe sum of the longitudinal plane principal stresses is indicated.
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