CN114062489A - Grading type monitoring method for crack depth of roll neck of leveling roll - Google Patents
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Abstract
The invention discloses a graded monitoring method for crack depth of a roll neck of a leveling roll. The method has relatively simple operation action, and can judge the crack depth more quickly so as to judge whether the roll needs to be changed. The invention provides a quick and simple technical means for avoiding sudden failure fracture, and can accumulate and form a corresponding judgment basis (set interval threshold value) according to the prior fracture condition data so as to simplify the subsequent monitoring and pre-judging risk process.
Description
Technical Field
The invention relates to a roller flaw detection technology, in particular to a grading type monitoring method for the crack depth of a roll neck of a leveling roller.
Background
The rollers of the temper mill used on a production line such as cold rolling and the like in the steel rolling process have certain quantity of roll neck fracture accidents, such as the conditions of the supporting roll and the working roll used by the following temper mill: the failure analysis result can clearly understand the roll neck fracture accident. After the broken roll is used for a certain period, although no obvious abnormality is found in the past use and grinding records, the shaft neck of the working roll under the temper mill is broken in the production process, and the design life is far from being reached.
The flattening machine rollers used on production lines such as cold rolling and the like in the steel rolling process have a certain number of roller neck fracture accidents, and relate to the supporting rollers and the working rollers used by the flattening machine. After many temper roll neck fracture failure analyses, the following clear findings have been made for roll neck fracture incidents: the planisher roll neck is equipped with the retaining ring, and the retaining ring is interference fit with the roll neck, and roll neck step root circular arc chamfer is stress concentration position. Through sampling analysis of actual samples of the broken shaft heads and fine observation of fractures and related parts, multi-source fatigue extension fractures caused by stress concentration are mostly found. The roll neck part is broken under the action of large-amplitude unidirectional bending stress, and the step of the fatigue fracture has a ratchet-shaped appearance, and a large-area transition area and an instantaneous fracture area. The temper roll neck break is typically located at the R-arc to cylindrical transition area of the neck variable diameter.
Due to the reason, after the broken roll is used for a certain period, although no obvious abnormality is found in the conventional use and grinding records, the shaft neck of the working roll under the temper mill is broken in the production process, and the design life is not reached. According to the process design, a leveling roller manufacturing factory can hot-install the water retaining ring in the area when manufacturing the working roller, and the position cannot be seen in the using and maintaining processes of the working roller at ordinary times, so that the difficulty in the prior art is caused for the hidden trouble investigation of failure accidents at the position.
Because the position of the crack source is covered by the water retaining ring, no moving space for placing the monitoring sensor exists near the position, and the detection and analysis of the cracking degree have certain difficulty.
Although the existing nondestructive detection methods are numerous, the nondestructive detection technologies aiming at crack detection are more, such as coloring, electromagnetism, ultrasound, eddy current, ray and the like, the practical requirements for monitoring the crack depth are difficult to meet through analysis under the condition of flattening the roll collar of the roll collar, and the crack depth monitoring method at the roll neck of the roll collar is required to be designed specially so as to meet the practical production rhythm most economically and efficiently.
The existing monitoring methods mainly comprise the following types, but the depth monitoring of the roll neck crack of the leveling roll cannot be realized:
1) x-ray nondestructive testing: starting from the discovery of roentgen, with the basic theoretical research and industrial progress, the film detection has been developed to several categories such as computer-aided imaging ray (CR), Digital Ray (DR), Computer Tomography (CT), compton imaging, neutron detection, etc., and the conventional defect detection has been developed to the directions of material organization, structure, residual stress, accumulated damage and precise measurement of dimension of components and component life evaluation. However, most of X-ray inspection methods are penetration methods, which deteriorate sensitivity, and are not suitable for volume samples, and are inconvenient to implement on site.
2) Magnetic powder detection: is one of the most popular and convenient conventional detection, and is widely applied to military industries and special equipment such as aerospace, metallurgical tools, mechanical manufacturing, atomic energy, weapons and the like. Magnetic powder detection is mainly used for semi-finished products and raw materials, bars, steel billets, forgings, castings and the like are widely used, and welding parts, large castings, in-service steel structures and the like are also used. But the method is not feasible due to the blocking of the water retaining ring and the fact that magnetic powder detection is only used for surface defect detection.
3) Ultrasonic detection: the method is various, and the conventional ultrasonic detection mainly aims at finding and evaluating the defects. Ultrasound technology that has advanced significantly in recent years includes: phased array technology, TOFT technology, laser ultrasonic technology, electromagnetic ultrasonic detection technology, ultrasonic guided wave detection technology, nonlinear ultrasonic technology and the like. However, sufficient consideration needs to be made on the aspect of field adaptability of detection equipment, and special practical consideration and design need to be provided for realizing that the self-method equipment can adapt to workpieces to be detected with different shapes, so that no existing technology is available at present.
4) And (3) penetration detection: the method is the conventional detection method which is most popularized and applied at the earliest, is widely applied to detecting the surface opening defects of most non-absorbent materials, such as steel and nonferrous metals, can also comprehensively detect the defects with complex shapes at one time, and is suitable for the field environment. The penetration test is also constrained by a water-retaining ring, as with the magnetic powder method, and is only used for surface defect detection.
5) Electromagnetic detection: the method is based on the change of electromagnetic performance of material to detect the defect and performance of material and member. The early electromagnetic nondestructive detection mainly comprises eddy current detection and magnetic leakage detection, and later developed metal magnetic memory detection, pulse eddy current detection, alternating current magnetic field detection, current disturbance detection, Barkhausen noise detection and magnetoacoustic emission technologies belong to the range of electromagnetic detection. This method is also constrained by water-stop rings, as is the magnetic powder method, and is also mostly used for defect detection over a limited depth range of the surface.
6) Acoustic emission detection: the phenomenon that a local source in a material quickly releases energy to generate transient elastic waves is called Acoustic Emission (AE) and is also called stress wave emission, and the acoustic emission is a natural phenomenon which occurs at any time in the nature. The acoustic emission detection technique can be used for on-line dynamic detection, but cannot be used for depth evaluation.
7) Infrared detection: the method is a technology for judging whether defects exist or not by receiving infrared rays emitted by an object, acquiring the surface temperature distribution of the object in an image form and reflecting the internal and external temperature conditions of the detected object, and has higher detection value particularly for the defects in non-metallic materials. This method is also constrained by the water retaining ring, as in the previous method, and is also used for surface defect detection.
8) Laser detection: since 1960 s the advent of lasers, laser holography technology became practical, and laser detection was mainly classified into 3 types of laser holography, laser speckle interference and laser dislocation speckle interference according to the imaging principle. The reason that laser holographic detection is not suitable is also limited by the water retaining ring, and detection cannot be carried out.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides a grading type monitoring method for the roll neck crack depth of a leveling roll, which can be used for more quickly and effectively monitoring the roll neck crack depth of the leveling roll by adopting ultrasonic waves.
The graded monitoring method for the crack depth of the roll neck of the leveling roll comprises the following steps:
a. the method comprises the following steps that a set of monitoring device is adopted, the monitoring device is provided with a plurality of levels of sensor groups, each level of sensor group is provided with a pair of same ultrasonic sensors with fixed intervals, one of the ultrasonic sensors is used for transmitting ultrasonic signals, the other ultrasonic sensor is used for receiving the ultrasonic signals, and the intervals between the two ultrasonic sensors of the plurality of levels of sensor groups are gradually increased in the same proportion;
b. use the minimum sensor group of interval earlier to arrange in the roller neck surface in the smooth roller breakwater ring outside along the roller shaft on to do unidirectional movement along the axis, simultaneously by an ultrasonic sensor to breakwater ring inside roll neck department slant transmission ultrasonic wave, another ultrasonic sensor is used for surveying echo signal: if no extreme value of the secondary reflected sound wave appears in the expected time range, judging that the roll neck is intact; if so, judging that the roll neck has cracks, and then adopting the next-stage sensor group to carry out measurement in the same way;
c. if the extreme value of the secondary reflected sound wave does not appear in the expected time range, judging that the length of the roller shaft corresponding to the crack depth is within the range between the distance between the sensor groups at the upper stage and the distance between the sensor groups at the upper stage; and if so, continuing to measure the next sensor group until the extreme value of the secondary reflected sound wave does not appear, and thus obtaining the length range of the broken pattern depth corresponding to the roll shaft.
In step b, the oblique emission angle of the ultrasonic sensor is 45 degrees.
Further comprising in step d: and setting a length threshold, and judging that roll replacement is needed when the length range of the roll shaft corresponding to the measured crack depth is larger than or equal to the threshold range.
In step b, longitudinal waves or transverse waves are selected as the detection echoes.
In step a, the distance between the sensors of the largest one of the multi-stage sensor groups is not less than the diameter of the roll neck.
The invention discloses a grading type monitoring method for crack depth of a roll neck of a leveling roll, which is characterized in that an ultrasonic sensor group formed by two ultrasonic sensors with different fixed intervals is displaced in a one-way mode along the axial direction, the length D value range on a roll shaft corresponding to the crack depth is finally determined by judging whether the maximum echo is received, the maximum echo signal is detected in the moving process of different sensor groups, and the sensor groups with different intervals correspond to different crack depth range sections. The method has relatively simple operation action, and can judge the crack depth more quickly so as to judge whether the roll needs to be changed. The invention provides a quick and simple technical means for avoiding sudden failure fracture, and can accumulate and form a corresponding judgment basis (set interval threshold value) according to the prior fracture condition data so as to simplify the subsequent monitoring and pre-judging risk process.
Drawings
FIG. 1 is a schematic diagram of the principle of the invention that the oblique incident wave does not strike a crack when a sensor group of class D1 is used;
FIG. 2 is a schematic diagram of the principle of oblique incidence wave striking the crack tip when a class D1 sensor array is used in the present invention;
FIG. 3 is a schematic diagram of the oblique incident wave striking a crack at a certain depth and receiving an expected maximum echo signal when a sensor group of class D1 is used in the present invention;
FIG. 4 is a schematic diagram of the present invention using a sensor group of D2 level, which can still receive the expected maximum echo signal in one-way movement;
FIG. 5 is a schematic diagram illustrating the principle of terminating the echo signal at the expected location during unidirectional movement when the Dn value sensor group is used in the present invention.
In the figure: roll neck 1, water retaining ring 2, crack 3, ultrasonic sensor T1, T2.
Detailed Description
The invention further describes a method for monitoring the crack depth of the roll neck of the leveling roll in a grading mode by combining the attached drawings and an embodiment.
Referring to fig. 1, the method for monitoring the crack depth of the roll neck of the temper roll in a grading manner includes the following steps:
a. a set of monitoring device is adopted, the monitoring device is provided with D1-Dn multistage sensor groups, each stage of sensor group is provided with a pair of identical ultrasonic sensors T1 and T2 with fixed intervals, one of the ultrasonic sensors is used for transmitting an ultrasonic signal T1, the other ultrasonic sensor is used for receiving the ultrasonic signal T2, and otherwise, the monitoring device can be connected with an ultrasonic flaw detector to carry out signal monitoring. The distance fixing can adopt a structure such as a fixed connecting frame for connecting two ultrasonic sensors. The distance values D1-Dn between the two ultrasonic sensors T1 and T2 of the multi-stage sensor group are gradually increased in the same proportion, and it needs to be noted that the smaller the proportion is, the smaller the measured range is, the closer the measured range is to the actual value, but the test times are correspondingly increased. In addition, the distance Dn between the sensors of the largest level should preferably not be less than the diameter of the roll neck, so that the distance value of the crack depth to be monitored at the roll neck on the roll shaft is always less than the distance between the sensors of a certain level in the D1-Dn level sensor group.
b. Firstly, a D1 grade sensor group with the smallest distance is used to be arranged on the outer surface of the roll neck outside the water retaining ring of the leveling roll along the roll shaft and move along the axis in a single direction, and meanwhile, an ultrasonic sensor T1 emits ultrasonic waves obliquely to the roll neck in the water retaining ring, wherein the emitting oblique angle theta is 45 degrees as an embodiment, and the other ultrasonic sensor T2 is used for detecting echo signals. The detection echo selects one of longitudinal wave and transverse wave in the ultrasound, and the following three conditions generally occur: as shown in fig. 1, when the oblique incident wave T1 does not hit the crack, it is obvious that no echo signal is received. As shown in fig. 2, in the case of unidirectional movement when T1 oblique incident waves hit the crack tip, since the length D of the crack depth D on the roll axis is greater than the distance D1 of the D1 ultrasonic sensor group used at this time, the echo signal may be observed but the maximum echo signal is not received. As shown in fig. 3, in the unidirectional motion, when the oblique incident wave of T1 hits the crack at a certain depth, T2 can receive the expected maximum echo signal. Therefore, the following monitoring judgment can be adopted: in an expected time range, if the extreme value of the secondary reflected sound wave does not appear in T2, judging that the roll neck is intact and no crack exists at all, and finishing monitoring; if so, judging that the roll neck has a crack, but the length D of the roll shaft corresponding to the crack depth is probably larger than D1, namely, in order to quantify the crack depth value, continuing the group test by using a next-stage D2-stage sensor group, and finding an ultrasonic sensor group closer to the D value;
c. when the next-stage sensor group (D2 stage) is used for carrying out measurement in the same mode, when the D2-stage sensor group carries out unidirectional movement monitoring, if an extreme value of secondary reflected sound waves does not appear in an expected time range, the length D of the crack depth on the roller shaft is judged to be smaller than the sensor distance D2 of the stage, and the length D value of the crack depth on the roller shaft is determined to be in the range of D1-D2 according to the sensor group distance D1 of the previous stage; if the crack depth is larger than the D1, and perhaps larger than the D2, as shown in fig. 4, in order to continue quantifying the crack depth, it is further necessary to continue the group test using the sensor group of the next level, i.e., D3, to find the ultrasonic sensor group closer to the D value, and thus repeat the measurement of the sensor group of the next level, i.e., Dn, until the extreme value of the secondary reflected sound wave does not appear (as shown in fig. 5) and the length D value range corresponding to the corresponding crack depth D on the roll axis is obtained according to the sensor group distance Dn-1 of the previous level.
According to the above process, there is always a group of ultrasonic sensors with interval of Dn values, which can not measure the expected ultrasonic echo extreme value at the expected time point during the moving process, and then it means that the D value corresponding to the measured crack depth is between Dn-1 and Dn value.
d. In addition, a length threshold corresponding to the crack depth can be set according to the accumulation of the conventional fracture condition data and the formation of a corresponding judgment basis, and when the measured D value range is greater than or equal to the threshold, the roll change is judged to be needed.
In conclusion, the invention designs a corresponding process monitoring method aiming at the main mode that the fatigue fracture is the tool failure and utilizing some characteristics of the fatigue failure, and is specially used for monitoring the cracking depth of the roll neck of the leveling roll. A faster and simpler technical means is provided for avoiding sudden failure fracture, and corresponding judgment basis is accumulated and formed according to the previous fracture condition data so as to simplify the subsequent monitoring and risk pre-judging process.
Claims (5)
1. A grading type monitoring method for the crack depth of a roll neck of a leveling roll is characterized by comprising the following steps:
a. the method comprises the following steps that a set of monitoring device is adopted, the monitoring device is provided with a plurality of levels of sensor groups, each level of sensor group is provided with a pair of same ultrasonic sensors with fixed intervals, one of the ultrasonic sensors is used for transmitting ultrasonic signals, the other ultrasonic sensor is used for receiving the ultrasonic signals, and the intervals between the two ultrasonic sensors of the plurality of levels of sensor groups are gradually increased in the same proportion;
b. use the minimum sensor group of interval earlier to arrange in the roller neck surface in the smooth roller breakwater ring outside along the roller shaft on to do unidirectional movement along the axis, simultaneously by an ultrasonic sensor to breakwater ring inside roll neck department slant transmission ultrasonic wave, another ultrasonic sensor is used for surveying echo signal: if no extreme value of the secondary reflected sound wave appears in the expected time range, judging that the roll neck is intact; if so, judging that the roll neck has cracks, and then adopting the next-stage sensor group to carry out measurement in the same way;
c. if the extreme value of the secondary reflected sound wave does not appear in the expected time range, judging that the length of the roller shaft corresponding to the crack depth is within the range between the distance between the sensor groups at the upper stage and the distance between the sensor groups at the upper stage; and if so, continuing to measure the next sensor group until the extreme value of the secondary reflected sound wave does not appear, and thus obtaining the length range of the broken pattern depth corresponding to the roll shaft.
2. The method for the staged monitoring of the crack depth of the neck of a temper roll as claimed in claim 1, wherein: in step b, the oblique emission angle of the ultrasonic sensor is 45 degrees.
3. The method for the staged monitoring of the crack depth of the neck of a temper roll as claimed in claim 1, wherein: further comprising in step d: and setting a length threshold, and judging that roll replacement is needed when the length range of the roll shaft corresponding to the measured crack depth is larger than or equal to the threshold range.
4. The method for the staged monitoring of the crack depth of the neck of a temper roll as claimed in claim 1, wherein: in step b, longitudinal waves or transverse waves are selected as the detection echoes.
5. The method for the staged monitoring of the crack depth of the neck of a temper roll as claimed in claim 1, wherein: in step a, the distance between the sensors of the largest one of the multi-stage sensor groups is not less than the diameter of the roll neck.
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| 《钢轨探伤基本知识（2019版）》编委会: "《钢轨探伤基本知识》", 31 March 2019, 中国铁道出版社, pages: 145 - 147 * |
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