CN113740429B - Method for measuring ultrasonic flaw detection blind area at step of disc forging - Google Patents
Method for measuring ultrasonic flaw detection blind area at step of disc forging Download PDFInfo
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- CN113740429B CN113740429B CN202111035462.3A CN202111035462A CN113740429B CN 113740429 B CN113740429 B CN 113740429B CN 202111035462 A CN202111035462 A CN 202111035462A CN 113740429 B CN113740429 B CN 113740429B
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- 238000001514 detection method Methods 0.000 title claims abstract description 55
- 238000005242 forging Methods 0.000 title claims abstract description 44
- 238000000034 method Methods 0.000 title claims abstract description 31
- 239000000523 sample Substances 0.000 claims abstract description 26
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 14
- 238000007654 immersion Methods 0.000 claims abstract description 13
- 230000007547 defect Effects 0.000 claims description 8
- 238000003754 machining Methods 0.000 claims description 8
- 238000012795 verification Methods 0.000 claims description 7
- 238000005516 engineering process Methods 0.000 claims description 3
- 239000000463 material Substances 0.000 claims description 3
- 238000010586 diagram Methods 0.000 description 6
- 238000009933 burial Methods 0.000 description 3
- 238000007689 inspection Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000007822 coupling agent Substances 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000001066 destructive effect Effects 0.000 description 1
- 238000002592 echocardiography Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
Classifications
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/30—Arrangements for calibrating or comparing, e.g. with standard objects
Abstract
The invention relates to a method for measuring ultrasonic flaw detection blind areas at a step of a disc forging piece, which comprises the steps of preparing a reference block; starting an ultrasonic flaw detection system; moving the ultrasonic probe to the position above the flat bottom hole to be measured, and adjusting the angle of the ultrasonic probe, the plane position of the ultrasonic probe and the flat bottom hole and the gain of an ultrasonic flaw detector; pushing the movable step block in from the edge of the base block, moving along the other edge of the scale mark, observing an ultrasonic wave waveform chart until the echo of the flat bottom hole is changed and reduced, stopping moving when the echo height is 40% of full scale, and recording the plane distance between the movable step block and the center of the flat bottom hole, wherein the distance is a flaw detection blind area under the current test condition. By adopting the method provided by the invention, the blind area generated by objective existence of the step structure in the water immersion ultrasonic flaw detection process of the disc forging of the aeroengine can be rapidly determined, and the rule that the step of the disc forging influences the ultrasonic detection blind area is found and used for guiding process programming.
Description
Technical Field
The invention belongs to the technical field of disc forging detection, and particularly relates to a method for measuring ultrasonic flaw detection blind areas at steps of a disc forging.
Background
Ultrasonic inspection is a non-destructive inspection technique that utilizes the principle that ultrasonic energy is able to produce reflection, refraction and transmission at the interface of a component defect with a body to discover the component defect. The method is characterized in that a core disc forging of the aeroengine is required to be processed and used after qualified water immersion ultrasonic flaw detection, a multi-axis automatic ultrasonic detection system is generally adopted in the detection method, clean water is used as a coupling agent, sound waves generated by an ultrasonic probe are vertically incident to the surface of the disc forging, echoes from the bottom surface of the disc forging are received, and whether the part is qualified or not is judged by observing waveform changes between surface reflected waves and bottom waves. Before detecting the parts, the ultrasonic detection process rules of the disc forgings are required to be compiled, and ultrasonic detection dead zones (parts which cannot be monitored by ultrasonic waves) are determined. The blind area is generally considered as an undetectable area of the upper and lower surfaces of the part, and the size of the blind area of the upper and lower surfaces of the part is verified by actually manufacturing the blind area comparison test block of the upper and lower surfaces, so that the manufacturing of the forging blank is guided, and enough machining allowance is reserved.
The aeroengine disk consists of a hub, a web plate and a rim, a plurality of structural steps can appear after forging and machining, and whether the structural steps appear or not can bring blind areas for water immersion ultrasonic flaw detection has no standard or reference data.
Disclosure of Invention
Aiming at the defects existing in the prior art, the invention provides a method for measuring ultrasonic flaw detection blind areas at the steps of a disc forging.
The method for measuring the ultrasonic flaw detection blind area at the step of the disc forging comprises the following steps:
step one: preparing a water immersion flaw detection system, an ultrasonic probe and a reference block for verifying a step ultrasonic flaw detection blind area;
step two: connecting an ultrasonic probe to a water immersion ultrasonic flaw detection system, starting the system, and placing a base block on a detection platform of the water immersion ultrasonic flaw detection system;
step three: moving an ultrasonic probe to the position above a flat bottom hole to be measured, adjusting the angle of the ultrasonic probe to enable an ultrasonic sound beam to be perpendicular to the upper surface of a base block, placing a focus of the probe in the depth center of the base block, and simultaneously adjusting the plane positions of the probe and the flat bottom hole until the height of a reflected echo of the flat bottom hole is maximum, and adjusting the gain of an ultrasonic flaw detector at the moment to enable the echo of the flat bottom hole to reach 80% of full scale;
step four: pushing the movable step block into the base block from the edge of the base block, moving along the other edge of the base block along the scale line, observing an ultrasonic wave pattern until the echo of the flat bottom hole is changed and reduced, stopping moving when the echo height is 40% of the full scale, and recording the plane distance between the movable step block and the center of the flat bottom hole at the moment, wherein the distance is a flaw detection blind area under the current test condition;
step five: and replacing the movable step test blocks with different thicknesses, and repeating the first to fourth steps to obtain specific flaw detection blind areas of the steps with different heights of the disc forging in the forging.
The material and the processing technology of the reference block are the same as those of the detected disc forging.
The reference block comprises a base block and a plurality of movable step blocks, the height of the base block is the same as the thickness of the disc forging to be detected, and the height of the movable step blocks is the same as the height of steps of the disc forging after machining and is used for simulating the heights of the steps of the disc forging after machining.
The upper surface of the base block is provided with scale marks along the length direction for size calibration in the blind area verification process.
The base block is cuboid, steps with different heights are upwards arranged from the bottom, and flat bottom holes are formed in the surface of the steps, so that flat bottom holes with different depths from the upper surface of the base block are formed, and the capability of detecting defects with different depths by ultrasonic flaw detection is verified.
The movable step block comprises a plurality of square blocks with different heights.
The beneficial effects of the invention are as follows: the invention provides a method for measuring ultrasonic flaw detection blind areas at disc forging steps, which is based on the detection method, and can accurately find the corresponding relation between the step heights and the ultrasonic flaw detection blind areas, namely, the higher the step is, the larger the ultrasonic flaw detection blind areas (areas which cannot be detected) are. The method provided by the invention can be used for rapidly determining the blind area generated by objective existence of the step structure in the water immersion ultrasonic flaw detection process of the disc forging of the aeroengine, finding out the rule that the step of the disc forging influences the ultrasonic detection blind area, guiding the process to compile, further improving the processing process and the ultrasonic flaw detection process of the disc forging, guiding the step to be avoided in the processing process of the forging to eliminate the flaw detection blind area, or selecting a more suitable probe, such as reducing the ultrasonic wafer size of the probe or increasing the focusing length, so as to reduce the flaw detection blind area, ensure the product quality and reduce the missed inspection risk of the product.
Drawings
FIG. 1 is a schematic diagram of a base block provided by an embodiment of the present invention;
FIG. 2 is a schematic diagram of a movable step block according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a blind zone verification process according to the present embodiment by using the method provided by the present invention;
FIG. 4 is an ultrasonic waveform diagram of the blind zone verification in the present embodiment by the method of the present invention;
wherein,
1-basic block, 2-movable step block, 3-flat bottom hole, 4-scale mark and 5-ultrasonic probe.
Detailed Description
For better explanation of the present invention, for easy understanding, the technical solution and effects of the present invention will be described in detail below by way of specific embodiments with reference to the accompanying drawings.
The method for measuring the ultrasonic flaw detection blind area at the step of the disc forging comprises the following steps:
step one: the water immersion flaw detection system, the ultrasonic probe 5 and a reference block for verifying the ultrasonic flaw detection blind area of the step are prepared.
The material and the processing technology of the reference block are the same as those of the detected disc forging.
The reference block comprises a base block 1 and a plurality of movable step blocks 2, wherein the height of the base block 1 is the same as the thickness of a detected disc forging, and the height of the movable step blocks 2 is the same as the height of steps of the disc forging after machining and is used for simulating the height of the steps of the disc forging after machining.
The upper surface of the base block 1 is provided with scale marks 4 along the length direction for size calibration in the blind area verification process.
Step two: the ultrasonic probe 5 is connected to a water immersion ultrasonic flaw detection system, the system is started, and the base block 1 is placed on a detection platform of the water immersion ultrasonic flaw detection system.
The base block 1 is a cuboid, steps with different heights are upwards arranged from the bottom, flat bottom holes 3 are formed in the surface of the steps, and accordingly flat bottom holes 3 with different depths from the upper surface of the base block 1 are formed and used for verifying the capability of finding defects with different depths in ultrasonic flaw detection.
As shown in FIG. 1, in this embodiment, the width of the base block 1 is 50mm, the height is 100mm, the length is 350mm, seven steps with different heights are evenly formed from the bottom upwards, a flat bottom hole 3 with phi of 1.2mm×10mm is formed on the lower surface of each step, and the height of the bottom surface of the flat bottom hole 3 from the upper surface of the base block 1, namely, the burial depth of the flat bottom hole 3, is 10mm, 20mm, 30mm, 50mm, 70mm, 80mm and 90mm respectively, and the defects with the depths of 10mm, 20mm, 30mm, 50mm, 70mm, 80mm and 90mm are represented respectively (the defect size equivalent is 1.2 mm). Specifically, the results are shown in Table 1. In order to improve the verification accuracy, the height of the bottom surface of the flat bottom hole 3 from the upper surface of the base block 1 is increased, the number of the heights of the bottom surface of the flat bottom hole 3 from the upper surface of the base block 1 is not limited, and the greater the number is, the higher the verification accuracy is.
TABLE 1 details of the step height of the base block 1 and the burial depth of the flat bottom hole 3 in this embodiment
| Sequence number | Step height | Depth of flat bottom hole 3 | Depth of burial of flat bottom hole 3 |
| 1 | 20 | 10 | 10 |
| 2 | 30 | 10 | 20 |
| 3 | 40 | 10 | 30 |
| 4 | 60 | 10 | 50 |
| 5 | 80 | 10 | 70 |
| 6 | 90 | 10 | 80 |
| 7 | 100 | 10 | 90 |
As shown in fig. 3, the movable step block 2 comprises square blocks of several different heights. The schematic diagram of the movable step block 2 is shown in fig. 2, and specific heights of the plurality of movable step blocks 2 provided in the present embodiment are shown in table 2. The thickness of the movable step block 2 in this embodiment is 40mm, and the blind detection area is verified when the step height of the disc forging is 40mm and the height of the bottom surface of the flat bottom hole 3 from the upper surface of the base block 1 is 50 mm.
TABLE 2 details of the height of the moving step 2 of this embodiment
Step three: moving the ultrasonic probe 5 to the position above the flat bottom hole 3 to be measured, adjusting the angle of the ultrasonic probe 5 to enable the ultrasonic sound beam to be vertical to the upper surface of the base block 1, placing the focus of the probe at the depth center of the base block, wherein the height of the base block 1 is 100mm in the embodiment, so that the focus position of the probe in the embodiment is 50mm of the depth center of the base block, and simultaneously adjusting the plane positions of the probe and the flat bottom hole 3 until the height of the echo reflected by the flat bottom hole 3 is maximum, and adjusting the gain of an ultrasonic flaw detector at the moment to enable the echo of the flat bottom hole 3 to reach 80% of full scale, as shown in fig. 4 (a); wherein A is interface wave, namely reflected wave of the upper surface of the base block 1; b is reflected wave of the flat bottom hole 3, 80%; c is the bottom wave, namely the reflected wave of the bottom surface of the base block 1.
Step four: pushing the moving step block 2 from the edge of the base block 1, moving to the other edge along the graduation line 4, observing an ultrasonic wave waveform diagram until the echo of the flat bottom hole 3 changes and decreases, and stopping moving when the echo height is 40% of full graduation, as shown in fig. 4 (b), wherein a is an interface wave, namely a reflected wave of the upper surface of the base block 1; b is reflected wave of the flat bottom hole 3, 60%; c is the bottom wave, namely the reflected wave of the bottom surface of the base block 1. Recording the plane distance between the moving step block 2 and the center of the flat bottom hole 3, wherein the distance is 40mm step under the test condition, and the flaw detection blind area is formed at the position of 50mm of the disc forging piece.
Step five: and replacing the movable step test blocks with different thicknesses, and repeating the first to fourth steps to obtain specific flaw detection blind areas of the steps with different heights of the disc forging in the forging.
Claims (3)
1. The method for measuring the ultrasonic flaw detection blind area at the step of the disc forging is characterized by comprising the following steps of:
step one: preparing a water immersion flaw detection system, an ultrasonic probe and a reference block for verifying a step ultrasonic flaw detection blind area;
step two: connecting an ultrasonic probe to a water immersion ultrasonic flaw detection system, starting the system, and placing a base block on a detection platform of the water immersion ultrasonic flaw detection system;
step three: moving an ultrasonic probe to the position above a flat bottom hole to be measured, adjusting the angle of the ultrasonic probe to enable an ultrasonic sound beam to be perpendicular to the upper surface of a base block, placing a focus of the probe in the depth center of the base block, and simultaneously adjusting the plane positions of the probe and the flat bottom hole until the height of a reflected echo of the flat bottom hole is maximum, and adjusting the gain of an ultrasonic flaw detector at the moment to enable the echo of the flat bottom hole to reach 80% of full scale;
step four: pushing the movable step block into the base block from the edge of the base block, moving along the other edge of the base block along the scale line, observing an ultrasonic wave pattern until the echo of the flat bottom hole is changed and reduced, stopping moving when the echo height is 40% of the full scale, and recording the plane distance between the movable step block and the center of the flat bottom hole at the moment, wherein the distance is a flaw detection blind area under the current test condition;
step five: changing the movable step test blocks with different thicknesses, and repeating the first to fourth steps to obtain specific flaw detection blind areas of the steps with different heights of the disc forging in the forging;
the reference block comprises a base block and a plurality of movable step blocks, the height of the base block is the same as the thickness of the disc forging to be detected, and the height of the movable step blocks is the same as the height of steps of the disc forging after machining and is used for simulating the height of the steps of the disc forging after machining;
the upper surface of the base block is provided with scale marks along the length direction for calibrating the size in the blind area verification process;
the base block is cuboid, steps with different heights are upwards arranged from the bottom, and flat bottom holes are formed in the surface of the steps, so that flat bottom holes with different depths from the upper surface of the base block are formed, and the capability of detecting defects with different depths by ultrasonic flaw detection is verified.
2. The method for measuring ultrasonic flaw detection blind areas at steps of disc forgings according to claim 1, wherein the method comprises the following steps: the material and the processing technology of the reference block are the same as those of the detected disc forging.
3. The method for measuring ultrasonic flaw detection blind areas at steps of disc forgings according to claim 1, wherein the method comprises the following steps: the movable step block comprises a plurality of square blocks with different heights.
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| CN202111035462.3A CN113740429B (en) | 2021-09-03 | 2021-09-03 | Method for measuring ultrasonic flaw detection blind area at step of disc forging |
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| CN113740429B true CN113740429B (en) | 2024-02-02 |
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