CN112945699B - Method for manufacturing comparison sample for heat damage eddy current inspection acceptance standard - Google Patents
Method for manufacturing comparison sample for heat damage eddy current inspection acceptance standard Download PDFInfo
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- CN112945699B CN112945699B CN202110371263.3A CN202110371263A CN112945699B CN 112945699 B CN112945699 B CN 112945699B CN 202110371263 A CN202110371263 A CN 202110371263A CN 112945699 B CN112945699 B CN 112945699B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N1/00—Sampling; Preparing specimens for investigation
- G01N1/28—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q
- G01N1/44—Sample treatment involving radiation, e.g. heat
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N1/00—Sampling; Preparing specimens for investigation
- G01N1/28—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q
- G01N1/32—Polishing; Etching
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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
- G01N27/725—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables by using magneto-acoustical effects or the Barkhausen effect
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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
Abstract
The invention discloses a method for manufacturing a comparison sample for heat damage eddy current inspection acceptance standards, wherein a method for generating heat by grinding is adopted to manufacture a burn defect, the manufactured burn defect is consistent with a burn defect generated when the grinding of an actual workpiece is not proper, the manufactured burn defect has representativeness, and an evaluation conclusion is real and reliable when the heat damage eddy current inspection is carried out according to the sample; the manufacturing method is simple; the mode of the eccentric center hole can be used for manufacturing burn defects in a local area of the cylindrical sample, so that the condition that the whole circumferential surface is a burn area is avoided, and the effect is obvious when the method is used for eddy current detection and adjustment; the manufacturing process of the grinding burn defects with different severity degrees is easy to control, after the serious burn defects are generated at first, the grinding burn defects with different severity degrees are manufactured by adopting a burn surface delamination removal method, the operation is simple and controllable, and the method can be used for judging the thermal damage eddy current detection after the actual workpiece is ground and verifying eddy current detection equipment.
Description
Technical Field
The invention belongs to the nondestructive testing technology, and particularly relates to a method for manufacturing a comparison sample for the acceptance standard of thermal damage eddy current testing.
Background
When a high-strength steel workpiece is subjected to grinding processing, grinding burn is easily generated on the surface of the workpiece due to improper grinding parameters, and the workpiece fails in advance or the fatigue life is reduced due to the grinding burn, so that burn detection needs to be performed on the grinding surface. The traditional method for detecting burn is generally acid etching, but the method is a destructive detection method, acid and alkali in the detection process are harmful to human bodies, and more importantly, the method can only detect visually accessible areas. The method has the advantages of no damage, simple operation, no contact with a workpiece during detection, high detection speed and the like, and can also detect the burn defect after grinding of a deep inner hole.
Eddy current testing has not been fully applied as a burn detection method, primarily because there is no standard and standardized test block. At present, a Chinese patent with publication number CN103323304A discloses a standard sample manufacturing method for verifying heat injury Barkhausen detection sensitivity, a Chinese patent with publication number CN107340162A discloses a preparation method for a calibration sample for detecting grinding burn by a Barkhausen noise method, the two methods manufacture burn defect samples by a laser heating method, and the burn degree, size, shape and position of the burn defect are controllable; chinese patent publication No. CN10374946A discloses a method for manufacturing a standard test block for testing tempering acid etching of 300M steel. The burn defects manufactured by adopting a laser heating or tempering heat treatment mode and the burn defects generated by actual grinding have difference in surface stress and the like, some products require a defect sample generated by grinding to be used as an acceptance basis of the products, and the burn defects with different degrees of severity are not easy to obtain by a grinding method.
Disclosure of Invention
The invention aims to provide a method for manufacturing a comparison sample for the eddy current test acceptance standard of thermal damage, aiming at the problems that the burn defect manufactured by adopting a laser heating or tempering heat treatment mode is different from the grinding burn defect in the prior art, and burn defect samples with different severity degrees are not easy to obtain in a grinding mode.
The invention solves the technical problems through the following technical scheme: a method of making a reference specimen for use in thermal damage eddy current test acceptance criteria, comprising the steps of:
step 1: selecting solid round steel which is the same as a workpiece to be detected in material and heat treatment state, and manufacturing the solid round steel into a solid cylindrical sample, wherein the central axis direction of the solid cylindrical sample is consistent with the rolling direction;
step 2: respectively manufacturing an eccentric center hole on two end faces of the solid cylindrical sample, wherein the connecting line of the two eccentric center holes is parallel to the direction of the central axis;
and step 3: clamping the solid cylindrical sample by eccentric center top holes at two ends, and grinding and burning the solid cylindrical sample by using a grinding wheel, wherein no cooling liquid is applied in the grinding and burning process until the grinding part is seriously discolored, and a concave surface is formed at the grinding part;
and 4, step 4: respectively manufacturing a center hole at the right center of two end surfaces of the solid cylindrical sample, clamping the solid cylindrical sample by the center hole, normally grinding the circumferential surface of the solid cylindrical sample by using the grinding wheel, and applying cooling liquid in the normal grinding process until the circumferential surface and the concave surface in the step 3 are just ground flat, so as to obtain a serious burn defect sample No. 1;
and 5: repeating the steps 1-4, and re-manufacturing a serious burn defect sample No. 2;
step 6: performing burn defect verification on the serious burn defect sample 1# and the serious burn defect sample 2# to finish the manufacture of the serious burn defect;
and 7: grinding the circumferential surface of one of the serious burn defect sample 1# and the serious burn defect sample 2# for multiple times, and verifying the burn defect of the sample after each grinding until the burn area of the sample is changed from the serious burn defect to the slight burn defect or to the burn defect between the slight burn defect and the serious burn defect to obtain a sample with the slight burn defect or obtain a sample with the burn defect between the slight burn defect and the serious burn defect;
and step 8: and performing thermal damage eddy current detection on the serious burn defect sample, the slight burn defect sample and the burn defect sample between the slight burn defect and the serious burn defect to obtain the impedance amplitudes of the non-burn area and the burn area of each sample, and taking the impedance amplitudes corresponding to the burn defects with different severity as the grinding burn acceptance standard of the materials under the same heat treatment state to finish the manufacture of the burn contrast sample.
Further, in the step 2, the eccentric center hole deviates from the central axis by 0.2mm to 1mm, the diameter of the eccentric center hole is 20mm, the depth of the eccentric center hole is 30mm, and the chamfer angle is 2 multiplied by 30 degrees.
Further, in the step 3, the grinding wheel has a thickness of 50mm, a diameter of 350mm, a grain size of 60#, a material of single crystal corundum, and a hardness of K.
Preferably, in step 3, before the burn is ground, the grinding surface of the grinding wheel is ground by green silicon carbide oilstone to be dull.
Further, in the step 3, the grinding burn parameters are as follows: the linear speed of the grinding wheel is 14m/s, the rotating speed of the solid cylindrical sample is 20 revolutions per minute, the cutting depth is 0.08mm, the transverse feed amount is 10mm per workpiece revolution, and the grinding width is 50 mm.
Further, in step 4, before normal grinding, the grinding wheel is sharpened, and the normal grinding parameters are as follows: the linear speed of the grinding wheel is 28m/s, the rotating speed of the solid cylindrical sample is 60 revolutions per minute, the cutting depth is 0.005mm, and the transverse feed amount is 3mm per workpiece revolution.
Further, in the steps 6 and 7, the burn defect verification method is an acid etching method.
In the process of manufacturing the burn defect sample, the determination of the burn defect is carried out in an acid etching mode, and the result is reliable.
Further, in the step 7, grinding is performed for multiple times in a layered grinding and removing mode, and the grinding amount is 0.005mm each time.
Advantageous effects
Compared with the prior art, the invention has the advantages that:
1. the method adopts a method of generating heat by grinding to manufacture the burn defect, the manufactured burn defect is consistent with the burn defect generated when the grinding of the actual workpiece is not proper, the manufactured burn defect has representativeness, and the evaluation conclusion is real and reliable when the sample is used for carrying out the heat damage eddy current detection; the manufacturing method is simple;
2. the mode of adopting the eccentric center hole can make burn defect in the local area of the cylindrical sample, avoid the situation that the whole circumferential surface is the burn area, the effect is obvious when being used for eddy current detection and adjustment;
3. the manufacturing process of the grinding burn defects with different severity degrees is easy to control, after the serious burn defects are generated at first, the circumferential surface layer of the cylindrical sample can be removed through normal grinding layering, the verification of the burn defects is combined, the sample with slight burn or serious burn or the burn between the slight burn and the serious burn can be obtained, and the corresponding eddy current impedance amplitude value in the state can be used as the judgment standard for whether the workpiece is subjected to grinding burn or not;
4. the method can be combined with a burn defect verification method, can also be used for manufacturing burn defects with different degrees between slight burn and severe burn, is particularly suitable for establishing a heat damage eddy current detection acceptance standard, provides a basis for judging the heat damage defects of actual workpieces, can also be used for verifying and verifying the sensitivity of equipment, and can also be popularized and applied to manufacturing heat damage defect comparison samples of other detection methods, such as a Barkhausen noise detection method and an acid etching method.
Drawings
In order to more clearly illustrate the technical solution of the present invention, the drawings needed to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the following description are only one embodiment of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on the drawings without creative efforts.
FIG. 1 is a flow chart of a method of making a comparative sample for thermal damage eddy current test acceptance criteria in example 1 of the present invention;
FIG. 2 is a graph of eddy current test impedance magnitude for non-burned area and burned area of sample No. 2 of slight burn in example 1 of the present invention; FIG. 2a is a graph of the impedance magnitude of a non-burned area and FIG. 2b is the impedance magnitude of a burned area;
FIG. 3 is a graph of eddy current test impedance magnitude for non-burned area and burned area of a severe burn sample No. 1 in example 1 of the present invention; FIG. 3a is a graph of the impedance magnitude of a non-burned area and FIG. 3b is the impedance magnitude of a burned area;
FIG. 4 is a graph of eddy current test impedance magnitude for non-burned and burned areas of burn defect sample No. 3 between a minor burn and a major burn in example 2 of the present invention; fig. 4a is a graph of the impedance magnitude of a non-burned area and fig. 4b is the impedance magnitude of a burned area.
Detailed Description
The technical solutions in the present invention are clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the 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.
Example 1
As shown in fig. 1, the present embodiment provides a method for manufacturing a comparison sample for thermal damage eddy current inspection acceptance criteria, which includes the following steps:
1. preparation of a sample
Selecting 300M round steel, manufacturing a solid cylindrical sample No. 1 by adopting a machining mode, wherein the size of the sample No. 1 is phi 180mm multiplied by 80mm, the central axis direction of the sample No. 1 is consistent with the rolling direction, manufacturing an eccentric center hole on each of two end faces of the solid cylindrical sample No. 1, and the connecting line of the two eccentric center holes is parallel to the central axis direction.
In the embodiment, the eccentric center hole deviates from the central axis of the sample No. 1 by 1mm, has the diameter of 20mm and the depth of 30mm, and is chamfered by 2 multiplied by 30 degrees. The purpose of the eccentric center hole is to make the burn defect produced later be a partial surface rather than the whole circumferential surface, so that the obtained burn defect is also a partial surface rather than the whole circumferential surface, and the heat is more concentrated during grinding by the grinding wheel, and the burn is more easily produced.
2. Ready to grind grinding wheel
Preparing a grinding wheel for manufacturing a sample with heat damage defects, wherein the parameters of the grinding wheel are as follows: 50mm in thickness, 350mm in diameter, 60# in granularity, single crystal corundum material and K in hardness; and grinding the grinding surface of the grinding wheel by adopting green silicon carbide oilstone until the grinding wheel becomes blunt.
3. Defect of serious burn
Clamping the solid cylindrical sample 1# by using the eccentric center hole, and grinding and burning the solid cylindrical sample 1# by using the grinding wheel in the step 2, namely, not applying cooling liquid in the grinding process until the grinding part is seriously discolored, so that the serious burn defect is formed, and at the moment, forming a shallow concave surface at the grinding part relative to an unground area.
In this embodiment, the grinding burn parameters are: the linear speed of the grinding wheel is 14m/s, the rotating speed of the solid cylindrical sample No. 1 is 20 r/min, the cutting depth is 0.08mm, the transverse feeding amount is 10 mm/workpiece r, and the grinding width is 50 mm.
4. And (3) dressing the sharpening of the grinding wheel again, respectively manufacturing a center hole at the centers of two end faces of the solid cylindrical sample No. 1, clamping the solid cylindrical sample No. 1 by the center hole, and normally grinding the whole circumferential face of the solid cylindrical sample No. 1 by using the dressed grinding wheel, namely applying cooling liquid in the normal grinding process to avoid burning until the whole circumferential face and the concave face are just ground flat to obtain the sample No. 1 with serious burn defects.
In this embodiment, the normal grinding parameters are: the linear speed of the grinding wheel is 28m/s, the rotating speed of the solid cylindrical sample No. 1 is 60 revolutions per minute, the cutting depth is 0.005mm, and the transverse feeding amount is 3mm per workpiece revolution.
5. Making another serious burn defect sample
Repeating the steps 1-4, and re-manufacturing a sample 2# with serious burn defects.
6. Severe burn defect verification
And (3) performing burn defect verification on the serious burn defect sample No. 1 and the serious burn defect sample No. 2 by adopting an acid etching method, wherein the acid etching color of a non-burn area is gray, the acid etching color of a slight burn area is dark gray, the acid etching color of a serious burn area is dark black, and even a white area surrounded by dark black appears, and the manufacture of the serious burn defect is completed through verification.
In the process of manufacturing the burn defect sample, the determination of the burn defect adopts an acid etching mode, and the result is reliable.
7. Making minor burn defect
And grinding the whole circumferential surface of the sample No. 2 for multiple times in a layered grinding removal mode according to normal grinding parameters, wherein the grinding removal amount is 0.005mm each time, after each time of grinding removal, performing burn defect verification by adopting an acid etching method until the color of a burn area is gradually changed from dark black or white surrounded by dark black into dark gray, namely from severe burn defect to slight burn defect, and obtaining a slight burn sample No. 2.
8. Thermal damage eddy current inspection
The non-burned area and the burned area of sample 2# were scanned by the thermal damage eddy current probe, and the obtained impedance amplitudes are shown in fig. 2, as can be seen from fig. 2, the impedance amplitude of the non-burned area is about 20% of the full screen, the impedance amplitude of the burned area is about 40% of the full screen, the impedance amplitude of the burned area is about 2 times of the impedance amplitude of the non-burned area, and the burn defect detection signal is obvious.
Similarly, the thermal damage eddy current probe is used to scan the non-burned area and the burned area of sample 1#, and the obtained impedance amplitudes are shown in fig. 3, as can be seen from fig. 3, the impedance amplitude of the non-burned area is about 4% of the full screen, the impedance amplitude of the burned area is about 24% of the full screen, the impedance amplitude of the burned area is 6 times of the impedance amplitude of the non-burned area, and the burn defect detection signal shows very obvious.
Therefore, the impedance amplitudes of the non-burn area, the slight burn area and the severe burn area of the sample No. 1 and No. 2 can be obtained, and the impedance amplitudes corresponding to the slight burn and the severe burn are used as the grinding burn acceptance standard of the material under the same heat treatment state, namely the preparation of the burn comparison sample is completed.
Example 2
1. The severe burn defect sample No. 3 was prepared by the steps 1 to 6 in example 1.
2. Making burn defects intermediate between severe burn defects and minor burn defects
Grinding the whole circumferential surface of the sample No. 3 by normal grinding parameters for multiple times, wherein the removal amount of each grinding is 0.005mm, after each grinding removal, performing burn defect verification by adopting an acid etching method until the color of a burn area is gradually changed from dark black or white surrounded by dark black into a color between dark gray and dark black, namely, the color is changed from a serious burn defect into a burn defect between a serious burn defect and a slight burn defect, and obtaining a burn defect sample No. 3 between the serious burn defect and the slight burn defect.
3. Thermal damage eddy current inspection
The non-burned area and the burned area of sample 3# were scanned by using the thermal damage eddy current probe, and the obtained impedance amplitudes are shown in fig. 4, as can be seen from fig. 4, the impedance amplitude of the non-burned area is about 8% of the full screen, the impedance amplitude of the burned area is about 24% of the full screen, the impedance amplitude of the burned area is about 3 times of the impedance amplitude of the non-burned area, and the burn defect detection signal shows obvious.
Thus, the impedance amplitude of the burn between the slight burn and the serious burn in the No. 3 sample can be obtained, and the impedance amplitude corresponding to the burn between the slight burn and the serious burn is taken as the grinding burn acceptance standard of the material under the same heat treatment state, namely the manufacture of the burn comparison sample is completed.
The above disclosure is only for the specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can easily conceive of changes or modifications within the technical scope of the present invention, and shall be covered by the scope of the present invention.
Claims (8)
1. A method for making a reference sample for thermal damage eddy current test acceptance criteria, comprising the steps of:
step 1: selecting solid round steel which is the same as a workpiece to be detected in material and heat treatment state, and manufacturing the solid round steel into a solid cylindrical sample, wherein the central axis direction of the solid cylindrical sample is consistent with the rolling direction;
step 2: respectively manufacturing an eccentric center hole on two end faces of the solid cylindrical sample, wherein the connecting line of the two eccentric center holes is parallel to the direction of the central axis;
and step 3: clamping the solid cylindrical sample by eccentric center top holes at two ends, and grinding and burning the solid cylindrical sample by using a grinding wheel, wherein no cooling liquid is applied in the grinding and burning process until the grinding part is seriously discolored, and a concave surface is formed at the grinding part;
and 4, step 4: respectively manufacturing a center hole at the right center of two end surfaces of the solid cylindrical sample, clamping the solid cylindrical sample by the center hole, normally grinding the circumferential surface of the solid cylindrical sample by using the grinding wheel, and applying cooling liquid in the normal grinding process until the circumferential surface and the concave surface in the step 3 are just ground flat, so as to obtain a serious burn defect sample No. 1;
and 5: repeating the steps 1-4, and re-manufacturing a serious burn defect sample No. 2;
step 6: performing burn defect verification on the serious burn defect sample No. 1 and the serious burn defect sample No. 2 to finish the manufacture of the serious burn defect;
and 7: grinding the circumferential surface of one of the serious burn defect sample 1# and the serious burn defect sample 2# for multiple times, and verifying the burn defect of the sample after each grinding until the burn area of the sample is changed from the serious burn defect to the slight burn defect or to the burn defect between the slight burn defect and the serious burn defect to obtain a sample with the slight burn defect or obtain a sample with the burn defect between the slight burn defect and the serious burn defect;
and 8: and performing thermal damage eddy current detection on the serious burn defect sample, the slight burn defect sample and the burn defect sample between the slight burn defect and the serious burn defect to obtain the impedance amplitudes of the non-burn area and the burn area of each sample, and taking the impedance amplitudes corresponding to the burn defects with different severity as the grinding burn acceptance standard of the materials under the same heat treatment state to finish the manufacture of the burn contrast sample.
2. The method for manufacturing a reference sample for the acceptance of thermal damage eddy current test according to claim 1, wherein in the step 2, the eccentric apex hole is deviated from the central axis by 0.2mm to 1mm, the diameter of the eccentric apex hole is 20mm, the depth of the eccentric apex hole is 30mm, and the chamfer angle is 2 x 30 °.
3. The method for manufacturing the comparison sample for the thermal damage eddy current testing acceptance standard according to claim 1, wherein in the step 3, the grinding wheel has a thickness of 50mm, a diameter of 350mm, a granularity of 60#, a material of single crystal corundum and a hardness of K.
4. The method for manufacturing a comparison sample for the acceptance criteria of thermal damage eddy current testing as claimed in claim 1, wherein in the step 3, before grinding burn, the grinding surface of the grinding wheel is ground by green silicon carbide oilstone to be dull.
5. The method for manufacturing the comparison sample for the acceptance criterion of the thermal damage eddy current test according to any one of claims 1 to 4, wherein in the step 3, the grinding burn parameters are as follows: the linear speed of the grinding wheel is 14m/s, the rotating speed of the solid cylindrical sample is 20 revolutions per minute, the cutting depth is 0.08mm, the transverse feed amount is 10mm per workpiece revolution, and the grinding width is 50 mm.
6. The method for manufacturing the comparison sample for the thermal damage eddy current inspection acceptance standard according to any one of claims 1 to 4, wherein in the step 4, the grinding wheel is sharpened before normal grinding, and the normal grinding parameters are as follows: the linear speed of the grinding wheel is 28m/s, the rotating speed of the solid cylindrical sample is 60 revolutions per minute, the cutting depth is 0.005mm, and the transverse feed amount is 3mm per workpiece revolution.
7. The method for making a comparison sample for thermal damage eddy current test acceptance criteria of claim 1, wherein in steps 6 and 7, the burn defect verification method is an acid etching method.
8. The method for manufacturing a comparison sample for the acceptance criteria of thermal damage eddy current test according to claim 1, wherein in the step 7, grinding is performed for a plurality of times by using a layered grinding removal mode, and the grinding amount is 0.005mm each time.
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