CN113916629B - Test piece design and test method for hole edge surface defect detection probability test - Google Patents
Test piece design and test method for hole edge surface defect detection probability test Download PDFInfo
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- CN113916629B CN113916629B CN202111182243.8A CN202111182243A CN113916629B CN 113916629 B CN113916629 B CN 113916629B CN 202111182243 A CN202111182243 A CN 202111182243A CN 113916629 B CN113916629 B CN 113916629B
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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
- G01N1/286—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q involving mechanical work, e.g. chopping, disintegrating, compacting, homogenising
Abstract
The invention is thatThe test piece design and test method can realize efficient preparation of crack samples and improve test efficiency. Arranging four holes on the porous flat tensile test piece along the load application direction, thereby causing stress concentration on the test piece to serve as potential positions for crack initiation; determining a crack length interval [ a ] required by the test according to a sample interval possibly with missed detection on the PoD curve l ,a u ]By adjusting the size of the test piece and combining three-dimensional crack propagation simulation, the method ensures [ a ] l ,a u ]In a steady state crack propagation stage; and cutting the prefabricated notch by adopting electric sparks at the hole edge stress concentration position at one side of the test piece according to the direction inclined by 45 degrees, so that cracks with different lengths are initiated at the two sides of the test piece at the stress concentration position, the diversity of the crack sample length is effectively increased, and the modeling precision of the PoD curve is improved. According to the invention, the high-efficiency preparation of the test piece for the PoD test of the hole edge surface crack can be realized, and the test efficiency of PoD data acquisition is greatly improved.
Description
Technical Field
The invention relates to the field of aviation maintenance, in particular to a test piece design and test method for a hole edge surface defect detection probability (Probability of Detection, poD) test.
Background
The turbine component of the aeroengine works under the extreme service condition of high temperature and high rotating speed for a long time, so that the turbine component is required to bear alternating centrifugal heavy load and is required to be overlapped with thermal stress caused by large temperature difference between a disk center and a disk edge, and the service condition is extremely bad. In addition, the wheel disc and the disc ring parts usually need to be perforated due to the design requirements of bolting, ventilation and the like, so that stress concentration is caused, and fatigue failure is extremely easy to induce. Therefore, when the engine is subjected to factory return maintenance, nondestructive detection is usually performed so as to reduce the failure risk caused by fatigue fracture during the service period of the hole edge stress concentration part. To evaluate the effectiveness of the detection means employed in the return repair, a defect detection test must be performed to accumulate a large number of crack samples to quantify the randomness of the nondestructive test, which can be extremely costly to prepare directly with the components of the engine. Therefore, it is necessary to adopt a high-efficiency test piece preparation method, the preparation process of which needs to be capable of reproducing the formation process of hole edge defects, and the cost is reduced as much as possible on the premise of meeting a large number of cracks required for the test. The method has important significance for developing nondestructive flaw detection tests.
The preparation of the pore edge surface crack PoD test piece has the following remarkable problems: (1) How to reduce the number of prepared test pieces as much as possible under the condition of meeting the required minimum crack number of the test requirement so as to reduce the cost and accelerate the test speed, and meanwhile, the test pieces can be prevented from being broken in the test process so as to improve the test success rate. (2) How to improve the crack sample acquisition efficiency and simultaneously ensure that the propagation of fatigue cracks of adjacent holes in the test can not interfere with each other. (3) How to ensure that the detected crack sample is consistent with the crack form generated under the service condition of the real part. After reviewing the existing patents and literature, no method for preparing a PoD test specimen capable of solving the three core problems is found, and therefore, it is necessary to design a porous flat plate tensile specimen design and test method for the PoD test of hole edge surface cracks.
The invention patent CN109612806A designs a test piece suitable for surface PoD, but does not clearly describe the preparation and test methods of the test piece such as a mode of electric spark prefabrication gaps, a determination method of crack length and the like, and the different crack lengths of the two sides of the test piece are generated, so that the test piece is ensured not to break in stages in a fatigue test, which is an important condition for realizing the efficient preparation of a porous flat plate tensile test piece; meanwhile, the square punching mode can enable cracks initiated at the inner sides of the two holes to be mutually influenced, and the risk that the number of effective samples is reduced due to breakage of a test piece exists.
The invention patent CN104392122A discloses a probability life assessment method of crack PoD, which is mainly characterized by establishing a corresponding PoD model and carrying out probability life assessment.
The test pieces adopted by the prior documents' Li Zhenghong, xu Wu, zhang Xiaojing, the method for testing and analyzing fatigue crack propagation of porous multi-crack flat plates [ J ]. Aviation journal, 2018,39 (07): 154-162. "have porous characteristics, but the purpose of the adoption of the porous test pieces is to study the influence among multi-crack propagation, so that the design of the test pieces needs mutual interference in the crack propagation process;
related test procedures and evaluation procedures for non-destructive testing are given in the existing instruction manuals "Annis C, bray E, hardy H, et al, nondestine evaluation system reliability assessment [ J ]. United States Department of Defense, wright-Patterson AFB, handbook MIL-HDBK-1823,1999 ], wherein a method of prefabricating penetrating notches at large arcs on both sides of a test piece and preparing crack specimens is given. Under the action of fatigue load, the penetrating notch can generate crack samples with basically consistent lengths on the surfaces of two sides of the test piece, so that the diversity of crack samples of a single test piece is reduced, and the acquisition efficiency of the crack samples is reduced.
Disclosure of Invention
The invention solves the technical problems that: the defect of the prior art is overcome, the design and the test method of the porous flat plate tensile test piece for the hole edge surface crack PoD test are provided, the PoD test requirement is met, the number of cracks on a single test piece is effectively increased by using the porous flat plate tensile test piece, the efficient preparation of a crack sample for the hole Bian Biaomian crack PoD test is realized, and the acquisition efficiency of detecting cracks is effectively improved. The invention designs a porous flat plate tensile test piece, provides a test method for nondestructive testing randomness quantification of a hole Bian Biaomian crack, and effectively improves the preparation efficiency of detecting the crack, in particular to the PoD evaluation direction of the surface crack.
The technical scheme of the invention is as follows: a test piece design and test method for a hole edge surface defect detection probability test comprises the following steps:
step 1: four holes are distributed on the porous flat tensile test piece along the load application direction, stress concentration positions are formed on the test piece and serve as potential positions for crack initiation, crack propagation behaviors of the stress concentration positions are not affected by each other, 8 stress concentration positions are formed on one side of each test piece, 16 crack samples can be obtained on the two sides of each test piece at most, and the crack sample preparation efficiency is greatly improved;
step 2: determining a required crack length interval [ a ] according to a sample interval possibly with missed detection on a PoD curve by adopting a nondestructive detection technology l ,a u ]，a l 、a u The upper and lower boundaries of the crack length interval, respectively. Simultaneously, the load required by the fatigue test is calculated reversely through the crack length, and the critical crack length a is calculated through three-dimensional crack propagation finite element simulation IC And set a u ≤0.8a IC Ensure [ a ] l ,a u ]In a steady state crack propagation stage, when the crack length of a part of the test piece reaches a u The loading is stopped. If the requirements are not met, the geometric dimensions such as the aperture of the test piece, the width of the checking section and the like and the fatigue load are adjusted.
Step 3: preparing a porous flat plate tensile test piece according to the number of crack samples in advance; in order to accelerate the test speed and improve the preparation efficiency of the crack sample, the electric spark is adopted at the stress concentration part of the hole edge on one side of the test piece to cut the prefabricated notch in the 45-degree oblique direction.
Step 4: and carrying out a fatigue crack propagation test, loading a fatigue load on the surface of the hole edge to generate fatigue cracks, observing the crack length in real time in the fatigue test process, measuring the crack length after the fatigue test by a scanning electron microscope or an optical microscope, counting the number of obtained crack samples, and repeating the test until the number of the crack samples meets the minimum sample number criterion of the estimated matrix percentile value under the given confidence.
Further, in the step 1, four holes of the porous flat plate tensile test piece are arranged along the load application direction, and the purpose of arranging the holes along the load application direction is not to influence the stress distribution on the crack propagation path of the hole edge in the vertical load application direction, so as to ensure that the design of the porous structure does not cause additional influence on the crack propagation behavior of the hole edge; meanwhile, the porous structure can generate more stress concentration positions, so that a crack sample can be obtained efficiently.
Further, in the step 2, in order to ensure that the PoD value of the PoD model is close to 0 at the smaller defect size and the PoD value of the PoD model is close to 1 at the larger defect size, a proper crack length interval [ a ] is required to be determined l ,a u ]So that the defects are at the small size and the large sizeA certain number of data samples and pass through the crack length a u And (5) back calculating the load required by the fatigue test. Meanwhile, in order to prevent failure of a crack sample caused by fracture of a test piece in the fatigue test process, three-dimensional crack propagation numerical simulation is performed by adopting crack analysis software to obtain critical crack length a IC And the fatigue crack length is set to 80% a IC When the test is stopped, the test piece fracture caused by the dispersibility of the material can be avoided to the greatest extent;
in step 3, the hole edge stress concentration part at one side of the porous flat plate tensile test piece is cut into a prefabricated notch according to the 45-degree oblique direction by adopting electric spark, and the reasons of single-sided prefabricated notch and cutting according to the 45-degree oblique direction are that cracks with different lengths are initiated at the two sides of the test piece at the stress concentration part, so that the diversity of the crack sample length is effectively increased, and the modeling precision of the PoD model is ensured;
further, in the step 4, a crack conforming to the crack morphology of the hole Bian Biaomian is obtained by fatigue load loading. Aiming at the fluorescent penetration method commonly used in the nondestructive testing of the aeroengine, as the coloring of the fluorescent agent is related to the surface tension of the liquid, the coloring effect is mainly influenced by the geometric characteristics of crack tips, and the more sharp the crack tips are, the darker the corresponding coloring is. Therefore, in order to accurately describe the probability of detection of a true hole Bian Biaomian crack defect, it is necessary to ensure that the crack tip geometry of the test piece is consistent with the fatigue cracks generated by the true component during service. The stress and damage state of the real hole edge is simulated through a fatigue test, so that the geometric characteristics of the crack tip of the test piece can be ensured to be consistent with the fatigue crack on the surface of the hole edge.
The beneficial effects are that:
(1) The invention is mainly characterized in that from the test point of view, the number of cracks of a single test piece is increased through a porous characteristic test piece with crack propagation behaviors not mutually influenced, so that the preparation efficiency of a crack sample is improved, and the PoD test speed is accelerated.
(2) The invention improves the crack sample acquisition efficiency of a single test piece through the porous characteristic test piece, and the cracks have no interaction.
(3) However, the invention provides special requirements for the wire-cut direction of the electric spark, so that the crack lengths at two sides of the test piece are different, the diversity of the crack lengths is effectively increased, and the precision and the confidence of the PoD model are improved.
(4) The invention provides a design scheme of a porous flat plate test piece, wherein a single test piece can obtain 16 crack samples at most; the wire cut direction of the electric spark is limited, so that the crack lengths of the two sides of the test piece at the same hole edge position are obviously different, and the preparation efficiency and the diversity of crack samples in the PoD test are effectively improved.
In conclusion, compared with the prior art, the method provided by the invention has the advantages that technical progress is made in the aspects of hole edge surface crack preparation efficiency, crack length diversity and the like, so that the high-efficiency and high-quality preparation of the surface crack PoD test sample is realized.
Drawings
FIG. 1 is a schematic diagram of a porous flat tensile test piece with a PoD crack on the surface of a hole edge;
FIG. 2 is a schematic diagram of the crack length intervals required to fit a PoD curve;
FIG. 3 is a schematic illustration of steady state crack propagation intervals;
FIG. 4 is a schematic diagram of a preformed gap according to 45 degrees oblique direction using an electric spark in accordance with the present invention;
FIG. 5 is a schematic diagram of the crack observation position of the porous tensile test piece according to the present invention;
FIG. 6 is a schematic diagram of crack length measurement using an optical microscope/scanning electron microscope;
FIG. 7 is a graph showing the values of the detected crack lengths obtained by the testRelationship data with the true crack length a;
fig. 8 is a test result of developing the surface crack PoD test.
Detailed Description
The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are only some embodiments of the present invention, but not all embodiments, and all other embodiments obtained by those skilled in the art without the inventive effort based on the embodiments of the present invention are within the scope of protection of the present invention.
According to the embodiment of the invention, the invention mainly aims at the design and test method of the porous flat plate tensile test piece for the hole edge surface crack PoD test. The specific test embodiment is as follows:
step one: designing a test piece: four holes 2 are distributed on the porous flat tensile test piece 1 along the load application direction, and stress concentration parts 3 are arranged on two sides of each hole on one surface of the test piece, so that cracks can be initiated, as shown in figure 1; as shown in FIG. 2, the crack length interval [ a ] required for fitting the PoD curve is determined according to the adopted nondestructive testing technology l ,a u ]，a l 、a u The upper and lower boundaries of the crack length interval, respectively. At the same time, the load required by fatigue test is calculated back through crack length to ensure [ a ] l ,a u ]In a steady state crack growth stage (shown in figure 3) and simultaneously avoiding the influence of calculation errors, performing three-dimensional crack growth simulation through finite element simulation software (FRANC 3D), and calculating to obtain the critical crack length a IC And set a u ≤0.8a IC . If the requirements are not met, the geometric dimensions such as the diameter of the test piece hole 2, the width 4 of the checking section and the like or the fatigue load are adjusted;
step two: according to the confidence, reliability and error limit requirements of the Kong Bianlie line PoD test, the minimum sample number of the estimated parent percentile value is determined, and the calculation formula is as follows:
wherein the method comprises the steps ofs represents the mean and standard deviation of the sample population, respectively, < >>Representing the coefficient of variation from N test crack samplesCalculating to obtain; delta represents error limit, p represents reliability, a represents confidence, t a For the value of t distribution given confidence a, +.>For correction coefficient of standard deviation, u p Representing a standard normal offset. Nondestructive inspection generally takes delta=5%, p=99.9%, and confidence level (1-a) is 95%;
step three: preparing a porous flat plate tensile test piece according to the number of crack samples in advance; in order to accelerate the test speed and improve the preparation efficiency of crack samples, the prefabricated notch is cut by adopting electric sparks at the hole edge stress concentration part 3 of one side of the test piece according to the direction inclined by 45 degrees (shown in fig. 4), so that cracks with different lengths are initiated at two sides of the test piece at the stress concentration part, each test piece is provided with 4 through holes 2, each through hole 2 is provided with two stress concentration positions, and 16 observation positions are arranged on the front surface and the back surface of each through hole 2, as shown in fig. 5, so that the length diversity of the crack samples is effectively increased.
Step four: and carrying out a fatigue test, and loading the fatigue load to generate fatigue cracks on the surface of the hole edge. In the test process, at intervals of a certain number of cycles, a long-focus microscope is required to monitor the crack state of stress concentration parts on two sides of the porous flat-plate tensile test piece 1 in real time, and when the crack length reaches a at a certain position of the test piece u The test was stopped at that time. Before nondestructive testing is carried out on the test piece 1, measuring the crack length of the stress concentration position of each hole edge by adopting an optical microscope or a scanning electron microscope, as shown in fig. 6, so as to obtain the actual crack length of each sample;
step five: nondestructive testing is carried out on the porous flat plate tensile test piece 1 for carrying out the fatigue test, and in the nondestructive testing process, the testing environment (such as magnetic field, sound wave and light state) needs to be ensured to be consistent with the real testing process so as to ensure that the obtained data is accurate and reliable; after the test piece to be detected is prepared, a special test piece bag is required to be put into for storage, and a protective tape is stuck to protect the detection surface so as to avoid artificial damage such as scratches;
step six: obtaining crack length response outputAnd the true size a, as shown in fig. 7. Fitting the response output using a one-time polynomial form>Relationship with the true dimension a, namely:
wherein beta is 0 、β 1 Fitting by linear regression, f (a),In a, & gt, respectively>As a function of the argument beta 0 、β 1 Four presentation forms of the detection data can be used for mapping during fitting, including +.> And selecting the mode with the best linear correlation degree according to the result. For example, when->When the linear correlation degree of the type data relationship is strongest, let f (a) =log (a), and +.>F (a),>substituted into->Regression analysis is carried out, and fitting parameters beta are obtained by maximum likelihood estimation 0 、β 1 And (5) taking a value. Further, a normal model may be employed as a basic form of the PoD model:
wherein Q (z) i ) The cumulative probability distribution is the standard normal distribution, and mu and sigma are fitting parameters. Output by statistical responseFunction value of->The PoD model at a given confidence level is determined by standard deviation from the function value f (a) of the true dimension a. For example, with confidence α=95%, the predicted value +.>The confidence interval upper limit may be expressed as:
wherein, 1.645 is the corresponding independent variable value under the standard normal distribution confidence coefficient alpha=95%, y=f (a),confidence α=95% means that at this PoD value there is a 95% likelihood that the corresponding defect size falls to the left of the point. Finally, drawing a PoD-a curve, and obtaining the relation of crack length corresponding to detection probability from the graph.
The hole edge surface crack PoD test was performed using the test piece 1 of the present invention. Firstly, performing a fatigue crack growth test, wherein in the test process, a low-cycle fatigue test is performed under the conditions that the stress ratio Rsigma=0.1 and the temperature T=430 ℃ (the corresponding temperature of the checking part of the eccentric hole) and the three-dimensional crack growth is performedAfter finite element simulation, calculating to obtain that the crack length of the termination test is 2.2mm, carrying out multiple tests, and establishing a PoD model by using test results, wherein the obtained test results are shown in FIG. 8, curve A represents detection probability PoD values corresponding to different crack lengths when the confidence coefficient is 50%, and curve B represents detection probability PoD values corresponding to different crack lengths when the confidence coefficient is 95%; a, a 90/50 、a 90/95 The confidence levels are 50% and 95% for the crack lengths when the detection probability is 90%. Since the confidence interval upper and lower bounds are parallel to the median line of the linear regression fit (α=50%), the spacing is 1.645 σ y Thus, the data can be fitted directly to the resulting PoD curve (α=50%) and shifted to the right by 1.645 σ y The PoD curve with confidence α=95% can be obtained. At the moment, the detection randomness in the nondestructive detection process can be quantified through the surface crack PoD test, and the maximum size of the defect possibly missed by the detection technology is obtained, so that the detection result is effectively evaluated. Experiments show that the efficient preparation method of the test piece can improve the PoD test speed and reduce the test cost.
The above examples are provided for the purpose of describing the present invention only and are not intended to limit the scope of the present invention. The scope of the invention is defined by the appended claims. Various equivalents and modifications that do not depart from the spirit and principles of the invention are intended to be included within the scope of the invention.
Claims (5)
1. A test piece design and test method for a hole edge surface defect detection probability test is characterized by comprising the following steps:
step 1: four holes are distributed on the porous flat tensile test piece along the load application direction, stress concentration is caused on the test piece to serve as potential positions for crack initiation, crack propagation behaviors of the stress concentration positions are not mutually influenced, and at most 16 crack samples are obtained for each test piece;
step 2: determining a required crack length interval [ a ] according to a sample interval possibly with missed detection on a defect detection probability PoD curve by adopting a nondestructive detection technology l ,a u ]，a l 、a u Respectively are provided withThe critical crack length a is calculated by performing three-dimensional crack propagation simulation through finite element simulation software for the upper and lower boundaries of the crack length interval and simultaneously calculating the load required by the fatigue test through the crack length back calculation IC And set a u ≤0.8a IC Ensure [ a ] l ,a u ]In a steady state crack propagation stage, when the crack length of a part of the test piece reaches a u Stopping loading when the load is stopped;
step 3: preparing a porous flat plate tensile test piece according to the number of crack samples in advance; in order to accelerate the test speed and improve the crack preparation efficiency, an electric spark is adopted at the stress concentration part of the hole edge at one side of the test piece to cut a prefabricated notch according to the direction of an included angle of 45 degrees with the horizontal plane;
step 4: and carrying out a fatigue crack propagation test, loading a fatigue load to obtain a crack consistent with Kong Bianlie lines, observing the crack length in real time in the fatigue test process, measuring the crack length after the fatigue test by a scanning electron microscope or an optical microscope, counting the number of obtained crack samples, and repeating the test until the number of the crack samples meets the minimum sample number criterion of the estimated matrix percentile value under the given confidence.
2. The test piece design and test method for hole edge surface defect detection probability test according to claim 1, wherein: in the step 1, four holes of the porous flat tensile test piece are arranged along the load application direction, and the purpose of arranging the holes along the load application direction is not to influence the stress distribution on the crack propagation path of the hole edge in the vertical load application direction so as to ensure that the design of the porous structure does not cause additional influence on the crack propagation behavior of the hole edge; meanwhile, the porous structure has a plurality of stress concentration positions, and a crack sample can be obtained efficiently.
3. The test piece design and test method for hole edge surface defect detection probability test according to claim 1, wherein: in the step 2, in order to ensure that the PoD model is in the defect size<0.3a u Near 0 at defect size>0.7a u Features near 1, a suitable crack length interval [ a ] is determined l ,a u ]The defects have a preset number of data points distributed in a small-size area with PoD values of 0 and a large-size area with PoD values of 1 and pass through the crack length a u Back calculating the load required by the fatigue test; meanwhile, in order to prevent failure of a crack sample caused by fracture of a test piece in the fatigue test process, a three-dimensional crack propagation finite element simulation is developed to obtain a critical crack length a IC And is set to reach a crack length of 80% a IC The loading was stopped to avoid breaking of the test piece due to material dispersion.
4. The test piece design and test method for hole edge surface defect detection probability test according to claim 1, wherein: in the step 3, the porous flat plate tensile test piece adopts electric sparks to cut the prefabricated notch at the hole edge stress concentration part at one side of the test piece according to the inclined 45-degree direction, and the reasons of single-sided prefabricated notch and cutting according to the inclined 45-degree direction are that cracks with different lengths are initiated at the stress concentration part at two sides of the test piece, so that the diversity of the lengths of crack samples is effectively increased, and the modeling precision of a PoD curve is improved.
5. The test piece design and test method for hole edge surface defect detection probability test according to claim 1, wherein: in the step 4, obtaining cracks consistent with Kong Bianlie lines by fatigue load loading; aiming at a fluorescent penetration method commonly used in the nondestructive testing of an aeroengine, as the coloring of a fluorescent agent is related to the surface tension of liquid, the coloring effect is mainly influenced by the geometric characteristics of crack tips, and the sharper the crack tips are, the darker the corresponding coloring is; therefore, in order to accurately describe the detection probability of the true hole Bian Biaomian crack defect, the geometric characteristics of the crack tip of the test piece must be ensured to be consistent with the true crack; the fatigue tester generates fatigue load and simulates the stress state of the real hole edge, so that the geometric characteristics of the crack tip of the test piece can be ensured to be consistent with the real crack.
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