CN113053471A - Method for nondestructive online detection of Brinell hardness of fan main shaft - Google Patents
Method for nondestructive online detection of Brinell hardness of fan main shaft Download PDFInfo
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Abstract
The invention relates to a method for nondestructive online detection of Brinell hardness of a fan main shaft, which is characterized by comprising the following steps: constructing a constitutive model based on real tissue evolution by analyzing a Brinell hardness method and a Leeb hardness method and a relation between a fitting method and a fitting model and a process and parameters; then constructing a prediction model; and finally, embedding the model into a finite element system by a finite element analysis technology to obtain the hardness distribution rule under different process conditions. The advantages are that: the technical problem that the Brinell hardness of the fan main shaft cannot be accurately detected on line in a nondestructive mode in the prior art is solved on the whole, and a basis is provided for accurately evaluating the in-service state of the fan main shaft, accurately controlling the using process by a quality enhancing tool and prolonging the fatigue life of service parts. Compared with the prior art, the method can greatly reduce the cost of manpower and material resources, improve the efficiency and fill the blank of nondestructive online detection of the hardness of the fan main shaft in Richardson.
Description
Technical Field
The invention relates to a method for nondestructive online detection of Brinell hardness of a fan main shaft, in particular to a method for nondestructive online detection of Brinell hardness of a fan main shaft with the material grade of 42CrMo4, and belongs to the technical field of hardness test of metal materials.
Background
For the in-service unit, whether thermal power, wind power or other industries, if the in-service unit needs to be inspected in the period, the first method is to adopt a non-destructive method to detect the in-service unit, for example: hardness detection, nondestructive detection, on-site metallographic detection and the like. Because of the direct relationship between hardness and strength, engineering is often used to measure the quality of performance. The method for detecting the hardness on site generally uses a portable Richter scale, and the portable Richter scale has the advantages of small volume, light weight, simple and convenient test, convenience in carrying, high detection efficiency, slight damage to the test surface and the like, so that the portable Richter scale is widely applied to the site detection of in-service equipment.
Restricted by the prior art, the prior detection technology cannot accurately perform nondestructive online detection on the Brinell hardness of the fan main shaft with the material grade of 42CrMo 4.
Although the portable Richter hardness tester is widely applied to field detection of in-service equipment, no standard exists at present for adopting the Richter hardness value as a judgment basis. In general, the hardness value of the hardness is converted into the hardness value of the hardness. The conversion between the hardness in Rich and Brinell is now according to GB/T17394.4-2014 "metallic Material hardness test part 4: table 1 in the hardness value conversion table ], however, the test objects to which table 1 is applied are "carbon steel, low alloy steel, and cast steel", and strictly speaking, are not applicable to the fan main shaft; if the hardness is converted according to table 1, deviation is inevitably caused, and the actual hardness of the measured part cannot be reflected. Therefore, a comparison test is required to be carried out, and the conversion relation between the hardness in Rich and Brinell consistent with the conversion relation is found out so as to fill the blank of the hardness in Rich test standard of the fan spindle material.
Although GB/T17394.4-2014 "metallic Material hardness test part 1: no requirements relating to the comparative tests are mentioned in the test methods, but since GB/T17394.4-1998 "method for testing Metal Richter hardness" has clear requirements for the comparative tests: "for a specific material, to accurately convert the hardness value of the Leeb into other hardness values, a comparative experiment must be performed to obtain the corresponding conversion relation. ".
Disclosure of Invention
The invention aims to provide a method for nondestructive online detection of Brinell hardness of a fan main shaft, in particular to a method for nondestructive online detection of the Richter hardness of a fan main shaft with a material number of 42CrMo4, and provides a basis for accurate evaluation of the in-service state of the fan main shaft and accurate control of a quality enhancement tool on the use process on the basis of illustrating the relationship between a Brinell hardness method (dynamic test method) and a Richter hardness method (static test method), as well as the relationship between a fitting method and a fitting model and different processes and parameters.
The purpose of the invention is realized by the following modes:
a method for nondestructive online detection of Brinell hardness of a main shaft of a fan is characterized in that a constitutive model based on real tissue evolution is constructed by analyzing a Brinell hardness method (dynamic test method) and a Leeb hardness method (static test method) and by the relation between a fitting method and a fitting model and a process and parameters; then constructing a prediction model; and finally, embedding the model into a finite element system by a finite element analysis technology to obtain the hardness distribution rule under different process conditions.
The analysis specifically comprises the following steps: and analyzing the hardness distribution characteristics, change rules and the like.
The constitutive model of the real tissue evolution is implemented based on different processes, and comprises the following steps: annealing, normalizing and quenching and tempering.
The prediction model is as follows: and obtaining a confidence interval of the material at normal temperature according to the relationship between the Brinell hardness and the Rich hardness of the material and the expression of the constitutive model, and further obtaining an equation of the Rich hardness.
The embedding specifically means that a regression equation with a hypothesis test value P larger than 0.05 is obtained by verifying the significance of the equation by hypothesis test based on a finite element technology.
The invention relates to a system for realizing the method, which comprises the following steps: the device comprises a process implementation processing unit, a Brinell hardness and Leeb hardness test detection unit, a Brinell hardness and Leeb hardness modeling unit and a verification unit, wherein: the process implementation processing unit outputs microstructure change rules and transmits the microstructure change rules to the Brinell hardness and Leeb hardness test detection unit, the Brinell hardness and Leeb hardness test detection unit outputs hardness change rules and transmits the hardness change rules to the Brinell hardness and Leeb hardness modeling unit, and the Brinell hardness and Leeb hardness modeling unit outputs an analytical expression and transmits the analytical expression to the verification unit through a finite element technology, and compares the analytical expression with an output result of the Brinell hardness and Leeb hardness test detection unit.
The invention has the following beneficial effects:
the invention integrally solves the technical problem that the Brinell hardness of the fan main shaft with the material brand of 42CrMo4 can not be accurately detected on line without damage in the prior art.
Compared with the prior art, the method is based on the real evolution rule of the microstructure in the treatment process, the constitutive model suitable for Brinell hardness and Rich hardness of the 42CrMo4 finished fan main shaft is established, and the Brinell hardness distribution value of the 42CrMo4 finished fan main shaft can be accurately predicted. The invention provides a basis for realizing accurate evaluation of the in-service state of the main shaft of the fan, accurate control of the quality enhancement tool on the use process and improvement of the fatigue life of service parts. Compared with the prior art, the method can greatly reduce the cost of manpower and material resources, improve the efficiency and fill the blank of nondestructive online detection of the hardness of the fan main shaft in Richardson.
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FIG. 1 is a schematic flow chart of the present invention.
Detailed Description
Example 1
As shown in fig. 1, the present embodiment relates to a nondestructive online brinell hardness testing method for a fan main shaft with a material designation of 42CrMo4, wherein the material is composed of a large amount of sorbite and a small amount of ferrite, and the specific operation comprises the following steps:
step one, cutting a fan main shaft material with the material trade name of 42CrMo4 to prepare a sample 3 group. The 3 groups of samples were subjected to annealing, normalizing, and thermal refining. 1 piece of the three groups is selected from the three groups to be cut, embedded, polished and corroded to prepare a metallographic specimen, and the metallographic specimen is placed under an optical microscope to observe the microstructure appearance of the specimen.
Step two, respectively carrying out surface machining on the 3 groups of samples through a milling machine and a grinding machine on the basis of the step one, and carrying out a test on a Brinell hardness machine to obtain Brinell hardness data; and then respectively placing 3 groups of samples on a Brinell hardness machine, performing a Brinell hardness test near each Brinell hardness point on the premise of not influencing the detection result, performing a plurality of Brinell hardness test near each Brinell hardness point, and recording the average value of the plurality of the Brinell hardness test tests as 1 group of effective values of the Brinell hardness to obtain the Brinell hardness data corresponding to the Brinell hardness data.
Step three, on the basis of the step two, establishing a constitutive model suitable for the fan main shaft material with the material grade of 42CrMo4 based on the weight relation, wherein the model comprises model fitting correlation, and the expression is as follows:
where r is the model fitting correlation, xiThe hardness value is a value of the hardness in the Richter scale,
average value of the Leeb's hardness number, yiIs a value of the brinell hardness,
the brinell hardness values are averaged.
The weight relationship comprises: the weighting characteristics and the degree of deviation that its weight has from a single point.
The modeling process is specifically as follows:
the least square method is weighted according to the distance from a certain middle position, and the weight of the least square method is related to the obvious deviation of a single point, so that the numerical fitting method is selected as the least square method;
secondly, according to the definition and the property of the hardness, a fitting model is selected as a linear function, so that the model established on the basis is as follows: y = a + bx, where a, b are both constants, x is the hardness value in the Richter scale and y is the Brinell scale.
Thirdly, under different process conditions, the uniformity of the material is different, the prediction result has fluctuation, a confidence interval with the probability of 95% can be introduced for correction, and the range of the confidence interval is obtained, wherein the expression is as follows:
will be
Substituting the model formula y = a + bx to obtain delta, wherein
δ is a constant for the predicted value for model formula y = a + bx.
Fourthly, according to the constitutive model expression: y = a + bx, with confidence interval
And obtaining the constitutive equation of the 42CrMo4 fan main shaft material with various microstructure evolutions through the Brinell hardness value and the Richter hardness value in the second step.
Step (ii) ofFourthly, based on the finite element technology, adopting hypothesis testing to test the constitutive equation, wherein the expression of the hypothesis testing is as follows: | t->tα/2(n-2), wherein t is the t-test method statistic and n is the experimental number.
In this example, 9 pieces were processed in a lump and divided into 3 groups (1 group for each 3 pieces) of specimens having a size of 200 ﹡ 100 ﹡ 20mm, and 30 groups of data were finally obtained by measurement. Through specific practical experiments, under different process states, the obtained experimental data are as follows:
In conclusion, the Brinell hardness and the Rich hardness relation characteristics of the fan spindle material with the material grade of 42CrMo4 are different from those of carbon steel, low alloy steel and cast steel materials, and the method is based on the weight relation and different process analytic modeling methods, introduces a correlation prediction method and the finite element technical hypothesis test, so that the method has higher Brinell hardness prediction precision for nondestructive online detection of the fan spindle material with the material grade of 42CrMo4, and omits a final detection means of a Brinell hardness test with high cost and complex operation.
The foregoing embodiments may be modified in many different ways by those skilled in the art without departing from the spirit and scope of the invention, which is defined by the appended claims and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
Claims (8)
1. A method for nondestructive online Brinell hardness detection of a fan main shaft is characterized by comprising the following steps: constructing a constitutive model based on real tissue evolution by analyzing a Brinell hardness method and a Leeb hardness method and a relation between a fitting method and a fitting model and a process and parameters; then constructing a prediction model; and finally, embedding the model into a finite element system by a finite element analysis technology to obtain the hardness distribution rule under different process conditions.
2. The method for nondestructive online testing of brinell hardness of a fan spindle according to claim 1, wherein: the analysis refers to: and analyzing the hardness distribution characteristics and the change rule.
3. The method for nondestructive online testing of brinell hardness of a fan spindle according to claim 1, wherein: the constitutive model of the real tissue evolution is implemented based on different processes, and comprises the following steps: annealing, normalizing and quenching and tempering.
4. The method for nondestructive online testing of brinell hardness of a fan spindle according to claim 1, wherein: the prediction model is as follows: and obtaining a confidence interval of the material at normal temperature according to the relationship between the Brinell hardness and the Rich hardness of the material and the expression of the constitutive model, and further obtaining an equation of the Rich hardness.
5. The method for nondestructive online testing of brinell hardness of a fan spindle according to claim 1, wherein: the embedding is based on a finite element technology, and the regression equation with the hypothesis testing value P larger than 0.05 is obtained by verifying the significance of the equation through hypothesis testing.
6. The method for nondestructive online testing of brinell hardness of a fan spindle according to claim 1, wherein: the system for realizing the method comprises the following steps: the device comprises a process implementation processing unit, a Brinell hardness and Leeb hardness test detection unit, a Brinell hardness and Leeb hardness modeling unit and a verification unit, wherein: the process implementation processing unit outputs microstructure change rules and transmits the microstructure change rules to the Brinell hardness and Leeb hardness test detection unit, the Brinell hardness and Leeb hardness test detection unit outputs hardness change rules and transmits the hardness change rules to the Brinell hardness and Leeb hardness modeling unit, and the Brinell hardness and Leeb hardness modeling unit outputs an analytical expression and transmits the analytical expression to the verification unit through a finite element technology, and compares the analytical expression with an output result of the Brinell hardness and Leeb hardness test detection unit.
7. The method for nondestructive online testing of brinell hardness of a fan spindle according to claim 1, wherein: the material of the fan main shaft is 42CrMo 4.
8. The method for the nondestructive online testing of the Brinell hardness of the main shaft of the wind turbine as claimed in claim 7, wherein: the specific operation comprises the following steps:
cutting a fan main shaft material with the material brand of 42CrMo4 into 3 groups of samples, and respectively carrying out annealing treatment, normalizing treatment and quenching and tempering treatment on the 3 groups of samples; 1 piece of the three groups is selected from the three groups to be cut, embedded, polished and corroded to prepare a metallographic specimen, and the metallographic specimen is placed under an optical microscope to observe the microstructure appearance of the specimen;
step two, respectively carrying out surface machining on the 3 groups of samples through a milling machine and a grinding machine on the basis of the step one, and carrying out a test on a Brinell hardness machine to obtain Brinell hardness data; then respectively placing 3 groups of samples on a Brinell hardness machine, performing a Brinell hardness test near each Brinell hardness point on the premise of not influencing the detection result, performing a plurality of Brinell hardness test near each Brinell hardness point, recording the average value of the plurality of the Brinell hardness test tests as 1 group of effective values of the Brinell hardness, and obtaining the Brinell hardness data corresponding to the Brinell hardness data;
step three, on the basis of the step two, establishing a constitutive model suitable for the fan main shaft material with the material grade of 42CrMo4 based on the weight relation, wherein the model comprises model fitting correlation, and the expression is as follows:
where r is the model fitting correlation, xiThe hardness value is a value of the hardness in the Richter scale,
average value of the Leeb's hardness number, yiIs a value of the brinell hardness,
the brinell hardness values are averaged. (ii) a
The weight relationship comprises: the weighting characteristics and the degree of deviation that its weight has from a single point;
the modeling process is specifically as follows:
selecting a numerical fitting method as a least square method;
selecting a fitting model as a linear function, and establishing the model as follows: y = a + bx, wherein a, b are both constants, x is the hardness value in the Richter scale and y is the hardness value in the Brinell scale;
introducing a confidence interval with the probability of 95% for correction to obtain the range of the confidence interval, wherein the expression is as follows:
will be
Substituting the model formula y = a + bx to obtain delta, wherein
Is a predicted value for model formula y = a + bx, δ being a constant;
fourthly, according to the constitutive model expression: y = a + bx, with confidence interval
And obtaining the constitutive equation of the 42CrMo4 fan main shaft material with various microstructure evolutions by the Brinell hardness value and the Richter hardness value in the second step;
step four, based on the finite element technology, adopting hypothesis testing to test the constitutive equation, wherein the expression of the hypothesis testing is as follows: | t->tα/2(n-2), wherein t is the t-test method statistic and n is the experimental number.
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| CN114112722A (en) * | 2021-10-29 | 2022-03-01 | 上海汇众萨克斯减振器有限公司 | Regression equation-based method for evaluating maximum yield stress of metal rod during bending |
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