CN115684350A - Nondestructive flaw detection method for metal roller - Google Patents
Nondestructive flaw detection method for metal roller Download PDFInfo
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- CN115684350A CN115684350A CN202211349633.4A CN202211349633A CN115684350A CN 115684350 A CN115684350 A CN 115684350A CN 202211349633 A CN202211349633 A CN 202211349633A CN 115684350 A CN115684350 A CN 115684350A
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Abstract
The invention relates to the technical field of nondestructive inspection, and provides a metal roller nondestructive inspection method which comprises the following steps of S1, debugging an ultrasonic flaw detector, and calibrating the ultrasonic flaw detector; s2, finding two end points of the defect along the axis direction, and recording the numerical values of the sound path, the horizontal distance and the depth displayed on the interface of the ultrasonic flaw detector; s3, finding out the corresponding arc length and depth; s4, after finding out the corresponding arc length and depth numerical values, measuring the other end point of the arc length on the surface of the metal roller, and measuring point positions corresponding to the corresponding depth along the radial direction by using a millimeter scale ruler; s5, moving the probe along the circumferential direction of the metal roller, finding out two vertexes with the minimum depth, and respectively recording the sound path, the horizontal distance and the depth value displayed on the interface of the ultrasonic flaw detector. Through the technical scheme, the problems that sound energy loss is serious when the metal roller is detected by an ultrasonic technology in the prior art, and defects cannot be accurately positioned and the defect area and the defect height cannot be measured when the defects are found are solved.
Description
Technical Field
The invention relates to the technical field of nondestructive inspection, in particular to a nondestructive inspection method for a metal roller.
Background
Nondestructive inspection is to detect whether a defect or unevenness exists in an object to be inspected and determine the state of the object to be inspected without damaging or affecting the usability of the object. The method for detecting the flaw in the metal generally adopts ultrasonic nondestructive flaw detection, and is characterized by strong penetrating power, high detection efficiency, timely detection result and wide application range.
Carry or centre gripping steel billet, steel sheet, shaped steel etc. through the metal roller generally in the metallurgical process of steel plant, because the steel billet forms under the high temperature state, especially to the roller that plays the clamping action, receives the influence of pressure, high temperature, external resistance and transmission power, long-time operation back inside can produce the fracture defect, especially hollow roller keyway root fracture is general, harm is serious, the fracture of the different degree of depth can cause the harm phenomenon of not equidimension. In the prior art, an ultrasonic detecting instrument is used, and comprises two probes, namely a straight probe and an inclined probe, wherein the two probes are contacted with the surface of a roller, whether defects exist is judged through a waveform received by the flaw detector, but because a metal roller is an arc surface, the two probes cannot be well contacted with the surface of the roller, the ultrasonic sound energy loss is serious, the defects cannot be detected even, and according to the conventional detection technology, the roller meeting the roller diameter requirement can only detect the length of the defects in the optimal state, but cannot accurately position the defects, the accurate depth of defect burying, the defect area and the height of the defects cannot be known, so that the damage degree of the defects cannot be judged once the defects are detected. Rollers with slight defects can continue to be used, but because the exact depth, location and area of the defect is not known, the result is: 1. the waste is serious because of blind replacement; 2. and the continuous use causes serious potential safety hazard of equipment and even production stop.
Disclosure of Invention
The invention provides a nondestructive inspection method for a metal roller, which solves the problem that the depth, the area and the height of a defect per se cannot be accurately positioned when the metal roller is detected by ultrasonic inspection in the related technology.
The technical scheme of the invention is as follows:
a nondestructive inspection method for metal rollers comprises the following steps
S1, preparing an ultrasonic flaw detector: debugging an ultrasonic flaw detector, and calibrating the ultrasonic flaw detector;
s2, detecting whether the metal roller has defects: abutting an inclined probe with the surface of the metal roller, then moving the probe, and detecting whether the metal roller has defects;
s3, finding two endpoints of the defect: after the defects are found, the metal roller moves along the axial direction of the metal roller, two end points of the defects along the axial direction are found, and the numerical values of the sound path, the horizontal distance and the depth displayed on the interface of the ultrasonic flaw detector are recorded;
s4, comparing data: comparing the numerical value recorded in the step S3 with the numerical value in a table of correspondence between the defect depth and the arc length of the metal roller, and finding out the corresponding arc length and depth, wherein the arc length is the arc length of the outer wall of the metal roller corresponding to the included angle between the front end surface of the oblique probe and the center point of the defect to the center of the metal roller, and the depth is the distance from the end point of the defect to the surface of the metal roller;
s5, determining the depth position of an end point: after finding out the corresponding arc length and depth value, taking the front end face of the oblique probe as a first reference, manually calculating the other end point of the arc length according to the arc length value or measuring the other end point of the arc length on the surface of the metal roller through an arc length ruler, then taking the end point as a second reference, and measuring the point position corresponding to the corresponding depth along the radial direction by using a millimeter scale ruler according to the depth value in the table, wherein the position at the moment is a defect end point;
s6, finding the defect vertex: moving the probe along the circumferential direction of the metal roller between the two defect endpoints, finding two vertexes with the minimum depth, and respectively recording the sound path, the horizontal distance and the depth value displayed on the interface of the ultrasonic flaw detector;
s7, determining a defect vertex: and repeating the steps S4-S5.
As a further technical scheme, the 'metal roller defect depth and arc length corresponding relation table' is measured by the following steps:
a1, manufacturing a plurality of artificial reflectors with different depths on a reference block with the same diameter and material as a roller, and recording the artificial reflectors in a book;
a2, debugging and calibrating an ultrasonic flaw detector;
a3, abutting the inclined probe with the surface of a reference block, and movably detecting the position of the artificial reflector;
a4, recording the sound path, horizontal distance and depth displayed by different artificial reflectors detected by the ultrasonic flaw detector;
and A5, sorting the recorded depth of the artificial reflector, the arc length corresponding to the detection of the artificial reflector, and the sound path, horizontal distance and depth displayed by the ultrasonic flaw detector to form a table.
As a further technical scheme, the bottom of the inclined probe is arc-shaped.
As a further technical scheme, the K value of the inclined probe is 0.69.
As a further technical scheme, the arc long ruler is an arc graduated scale with scales.
The working principle and the beneficial effects of the invention are as follows:
1. according to the method, the metal roller is measured by an ultrasonic flaw detector, then the position of the defect can be accurately found according to the comparison numerical value of a table of correspondence between the depth of the defect and the arc length of the metal roller, the height of the defect is measured, and the area of the defect is calculated, so that the damage degree of the defect of the metal roller is judged, whether the metal roller can be continuously used or not is judged, the waste of the metal roller is avoided, and the potential safety hazard to steel production line equipment is reduced;
2. in the invention, because a plurality of rollers with the same diameter are used in a steel plant, the rollers with the same roller diameter only need one corresponding relation table of the defect depth and the arc length of the metal roller to finish comparison in the detection process;
3. according to the invention, the inclined probe with the cambered surface at the bottom is adopted and matched with a proper K value, so that the loss of ultrasonic sound energy is avoided, and the accuracy and the stability of detection are improved.
Drawings
The present invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
FIG. 1 is a schematic view of the probe of the present invention;
FIG. 2 is a schematic view of an arc length scale according to the present invention;
FIG. 3 is a schematic diagram of a reference block structure according to the present invention;
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any inventive step, are intended to be within the scope of the present invention.
As shown in fig. 1 to 3, the present embodiment proposes
A metal roller nondestructive inspection method comprises the following steps:
s1, assembling and debugging an ultrasonic flaw detector, adopting an inclined probe, preferably adopting the inclined probe with an arc-shaped bottom surface, ensuring that all ultrasonic waves enter a metal roller and positioning accurately; the selected K value of the inclined probe is 0.69, and the axial defects of the metal roller with the ratio of the inner diameter to the outer diameter of more than 60 percent can be detected.
S2, the arc-shaped surface of the inclined probe is abutted against the surface of the metal roller, and then the inclined probe is moved to detect whether the metal roller has defects or not.
And S3, if the defect is detected, finding two end points of the defect along the axial direction of the metal roller according to an end point 6db method, and recording the sound path, the horizontal distance and the depth value which are displayed on the ultrasonic flaw detector and correspond to the two end points.
And S4, comparing the recorded numerical values with the numerical values in the metal roller defect depth and arc length corresponding relation table, and finding the same numerical values to obtain the arc length and the depth of the defect distance angle probe.
S5, an included angle between an incidence point of the inclined probe and a defect end point to the circle center of the metal roller corresponds to the arc length of the outer wall of the metal roller, namely the arc length recorded in the table, then the corresponding length is measured through an arc length ruler, the front end face of the inclined probe is taken as a reference when the arc length ruler is used for measuring, the other end point of the arc length is measured through the arc length ruler, the other end point of the arc length, the defect end point and the circle center of the roller are on the same straight line, then the length recorded with the depth in the table is measured through a graduated scale, the point measured by the arc length ruler is taken as a reference point when the graduated scale is used for measuring, the measurement is carried out on the straight line passing through the circle center of the inner wall of the metal roller, and the measured point is the position of the defect end point at the moment; in this step, the position of the defect may be close to the middle position in the axial direction of the metal roller, and at this time, the end point of the arc length may be measured by the arc length ruler, but during the measurement of the depth, the end point of the arc length may only be measured on the end surface of the metal roller, so after the end point of the arc length is measured by the arc length ruler, a point on the end surface of the metal roller, which is on the same straight line with the end point of the arc length, is found along the axial direction of the metal roller, and then the position of the end point of the defect is measured by using the scale according to the point.
S6, moving the two defect endpoints along the axial direction of the metal roller by using an inclined probe along the circumferential direction of the metal roller, finding the vertex of the defect by using an endpoint 6db method, and recording the sound path, the horizontal distance and the depth value displayed on the interface of the ultrasonic flaw detector for detecting the vertex of the defect; the two disadvantage vertices are the points of minimum depth.
S7, optionally repeating the steps S4-S5, and then measuring the defect vertex; the area of the defect can be calculated because the depth of the defect is accurate; can provide accurate basis for whether the metal roller can be used continuously.
In this step, because there may be a plurality of defects, the plurality of defects may or may not overlap in depth; when two end points of the defect are found, if the two defects have overlapped positions and cannot be distinguished, one end point can be selected from the two defects respectively, and the maximum length of the two defects is measured to be the maximum length of the defect. According to the method, the distance between two end points of the defect in the axial direction of the metal roller is the length of the defect, and the depth of two top points is subtracted from the depth of the two end points in the radial direction, and the height of the defect is calculated at the moment, so that the area of the defect can be calculated.
In the embodiment, the specific position of the defect can be known by measuring two end points of the defect, the length of the defect and the depth of the defect in the metal roller are also known, and the area of the defect can be calculated, so that whether the metal roller can be continuously used or not can be easily judged; moreover, the inclined probe with the arc-shaped bottom surface is adopted, so that all ultrasonic energy is ensured to enter the metal roller to the greatest extent, and the measurement is more accurate; because the same diameter of the roller used by the steel plant is large in quantity, the arc length of the roller diameter can be rapidly measured by customizing a standard arc length ruler, so that the position of the defect can be rapidly positioned.
The preparation method of the corresponding relation table of the depth of the metal roller defect and the arc length in the S4 comprises the following steps:
a1, purchasing or manufacturing a reference block with the same diameter and material as a metal roller, wherein the manufacturing of the reference block meets the requirements of related national standards, and then manufacturing artificial reflectors with different depths on the reference block, wherein the artificial reflectors are preferably long transverse holes with the diameter of 3mm, the axial direction of the long transverse holes is parallel to the axial direction of the reference block, and the length of the long transverse holes is 25mm; recording the depth of the defect;
a2, assembling and debugging the ultrasonic flaw detector and calibrating;
a3, abutting the inclined probe with the surface of a reference block, and movably detecting the position of the artificial reflector;
a4, recording a sound path, a horizontal distance and depth displayed when the ultrasonic flaw detector detects artificial reflectors of different depths;
a5, sorting the recorded depth of the artificial reflector and the sound path, horizontal distance and depth displayed by the ultrasonic flaw detector to form a corresponding relation table of the depth of the metal roller defect and the arc length; for example, table 1, records "Table of correspondence between depth of defect and arc length of Metal roller" for 300mm diameter Metal roller:
TABLE 1 "corresponding relationship between depth of defect and arc length of metal roller
Table 1 is merely an example, and may be designed according to the user's habit as long as the defect depth and the ultrasonic flaw detector numerical value display correspondence can be found.
The method in the embodiment can measure the numerical values displayed on the ultrasonic flaw detector corresponding to all the flaw depths on the reference block.
Preferably, the inclined probe used in the table for the correspondence between the depth of the defect of the metal roller and the arc length has the same K value and frequency as those of the inclined probe used in the actual detection of the metal roller.
In this embodiment, the position of the defect can be quickly found when the metal roller is detected by recording the numerical value displayed in the ultrasonic flaw detector corresponding to the depth of the defect in the reference block. Through the numerical values recorded in table 1, it can be known that when the ultrasonic flaw detector detects the radial flaw of the roller, the error value increases with the increase of the depth of the flaw, and the accurate position of the flaw can be measured by the method.
The present invention is not limited to the above preferred embodiments, and any modifications, equivalent substitutions, improvements, etc. within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (5)
1. The metal roller nondestructive inspection method is characterized by comprising the following steps
S1, preparing an ultrasonic flaw detector: debugging an ultrasonic flaw detector, and calibrating the ultrasonic flaw detector;
s2, detecting whether the metal roller has defects: abutting an inclined probe with the surface of the metal roller, moving the probe, and detecting whether the metal roller has defects or not;
s3, finding two endpoints of the defect: after the defects are found, the metal roller moves along the axial direction of the metal roller, two end points of the defects along the axial direction are found, and the numerical values of the sound path, the horizontal distance and the depth displayed on the interface of the ultrasonic flaw detector are recorded;
s4, comparing data: comparing the numerical value recorded in the step S3 with the numerical value in a table of correspondence between the defect depth and the arc length of the metal roller, and finding out the corresponding arc length and depth, wherein the arc length is the arc length of the outer wall of the metal roller corresponding to the included angle between the front end surface of the oblique probe and the center point of the defect to the center of the metal roller, and the depth is the distance from the end point of the defect to the surface of the metal roller;
s5, determining the depth position of an end point: after finding out corresponding arc length and depth values, taking the front end face of the oblique probe as a first reference, manually calculating the other end point of the arc length according to the arc length value or measuring the other end point of the arc length on the surface of the metal roller through an arc length ruler, then taking the end point as a second reference, and using a millimeter scale ruler to radially measure a point position corresponding to the corresponding depth according to the depth value in the table, wherein the position at the moment is a defect end point;
s6, finding the defect vertex: moving the probe along the circumferential direction of the metal roller between the two defect endpoints, finding two vertexes with the minimum depth, and respectively recording the sound path, the horizontal distance and the depth value displayed on the interface of the ultrasonic flaw detector;
s7, determining a defect vertex: and repeating the steps S4-S5.
2. The metal roller nondestructive inspection method according to claim 1, wherein the "table of correspondence between depth of defect and arc length of metal roller" is obtained by the steps of:
a1, manufacturing a plurality of artificial reflectors with different depths on a reference block with the same diameter and material as a roller, and recording the artificial reflectors in a book;
a2, debugging and calibrating an ultrasonic flaw detector;
a3, abutting the inclined probe with the surface of a reference block, and movably detecting the position of the artificial reflector;
a4, recording the sound path, horizontal distance and depth displayed by different artificial reflectors detected by the ultrasonic flaw detector;
and A5, sorting the recorded depth of the artificial reflector, the arc length corresponding to the detection of the artificial reflector, and the sound path, horizontal distance and depth displayed by the ultrasonic flaw detector to form a table.
3. The metal roller non-destructive inspection method according to claim 1, wherein the bottom of said angle probe is arc-shaped.
4. The method of claim 3, wherein the angle probe has a K value of 0.69.
5. The method of claim 1, wherein the arc length scale is an arc scale with scales.
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