CN117723629A - Nondestructive testing method for internal defects of engine crankshaft - Google Patents
Nondestructive testing method for internal defects of engine crankshaft Download PDFInfo
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- CN117723629A CN117723629A CN202311488101.3A CN202311488101A CN117723629A CN 117723629 A CN117723629 A CN 117723629A CN 202311488101 A CN202311488101 A CN 202311488101A CN 117723629 A CN117723629 A CN 117723629A
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- 230000007547 defect Effects 0.000 title claims abstract description 87
- 238000000034 method Methods 0.000 title claims abstract description 33
- 238000009659 non-destructive testing Methods 0.000 title claims abstract description 11
- 239000000523 sample Substances 0.000 claims abstract description 88
- 238000005498 polishing Methods 0.000 claims abstract description 16
- 238000007689 inspection Methods 0.000 claims description 10
- 238000004519 manufacturing process Methods 0.000 claims description 7
- 230000001681 protective effect Effects 0.000 claims description 7
- 239000010705 motor oil Substances 0.000 claims description 5
- 238000004140 cleaning Methods 0.000 claims description 4
- 239000007822 coupling agent Substances 0.000 claims description 4
- 230000030808 detection of mechanical stimulus involved in sensory perception of sound Effects 0.000 claims description 3
- 230000001066 destructive effect Effects 0.000 claims 9
- 238000012423 maintenance Methods 0.000 abstract description 4
- 230000009286 beneficial effect Effects 0.000 abstract description 2
- 239000007769 metal material Substances 0.000 abstract description 2
- 238000012360 testing method Methods 0.000 abstract description 2
- 238000001514 detection method Methods 0.000 description 22
- 230000008878 coupling Effects 0.000 description 2
- 238000010168 coupling process Methods 0.000 description 2
- 238000005859 coupling reaction Methods 0.000 description 2
- 239000006247 magnetic powder Substances 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 238000007920 subcutaneous administration Methods 0.000 description 1
- 230000003746 surface roughness Effects 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Abstract
The invention relates to a nondestructive testing method for internal defects of an engine crankshaft, and belongs to the technical field of physicochemical testing methods of metal materials. The technical scheme of the invention is as follows: selecting a proper ultrasonic transverse wave inclined probe according to the shaft diameter of the crankshaft, and polishing and debugging the ultrasonic transverse wave inclined probe; scanning the journal and the R angle arc of the crankshaft by using an ultrasonic transverse wave oblique probe, and judging the defects to be detected on the surface and the near surface of the crankshaft; and selecting a proper ultrasonic longitudinal wave straight probe according to the size of the crankshaft shaft diameter, polishing and debugging the ultrasonic longitudinal wave straight probe, scanning the crankshaft shaft diameter by using the ultrasonic longitudinal wave straight probe, and judging the defect to be detected in the crankshaft. The beneficial effects of the invention are as follows: the ultrasonic longitudinal wave straight probe and the ultrasonic transverse wave oblique probe are combined to detect the defects of the crankshaft, so that the operation is simple and easy, the use and maintenance cost is low, and the defects of the surface, the near surface and the inside of the diameter and the R angle of the crankshaft can be comprehensively detected.
Description
Technical Field
The invention relates to a nondestructive testing method for internal defects of an engine crankshaft, and belongs to the technical field of physicochemical testing methods of metal materials.
Background
The nondestructive testing process of the defects of the traditional engine crankshaft generally adopts magnetic powder detection and ultrasonic longitudinal wave straight probe detection. However, in the actual production process, the conventional detection method is found to be incapable of detecting all the defects of the crankshaft. The magnetic powder inspection can detect the surface defect of the crankshaft; the ultrasonic longitudinal wave straight probe can detect internal defects of a crankshaft, but has flaw detection blind areas within a certain area range from the surface, such as near-surface defects, internal sheet defects perpendicular to a detection surface (or forming a certain angle with the detection surface), special position defects (refer to R arc internal defects), and the like, wherein the R angle arc position is called a dangerous section, is a focus attention position for detecting the defects of the crankshaft, the influence of the surface and the near-surface defects on the fatigue life of the crankshaft is particularly important, and the traditional nondestructive detection method can not detect the near-surface and the internal defects at the position rapidly and accurately.
The Chinese patent application CN 104280459A discloses an ultrasonic phased array detection method for internal defects at the R-angle circular arc of a crankshaft, which is based on the traditional process of nondestructive detection of the crankshaft, and the phased array detection method with a one-dimensional linear array probe with automatic deflection and focusing, which is added with a proper wedge, is applied to the detection of the internal defects of the crankshaft, so that the detection of the internal defects with equivalent size of more than 1mm at the journal and the R-angle circular arc can be realized by using one probe, and the defects of the method are that the used ultrasonic phased array detection probe is high in price and the use and maintenance cost.
The Chinese patent application CN 103134853A discloses a nondestructive testing method for a crankshaft, wherein the method for detecting the ultrasonic transverse wave inclined probe for detecting the welding seam is applied to the detection of internal defects of the crankshaft, so that the internal defects between 5mm and 50mm away from the surface and the internal defects of the arc of the R angle can be effectively detected, the defect in the region within 5mm away from the surface cannot be detected, and the potential danger of the defect which is closer to the surface in the actual use process of the crankshaft is larger.
Disclosure of Invention
The invention aims to provide a nondestructive testing method for internal defects of an engine crankshaft, which is simple and easy to operate, low in use and maintenance cost and capable of comprehensively detecting the surface, near surface and internal defects of the diameter and the R angle of the crankshaft by combining an ultrasonic longitudinal wave straight probe and an ultrasonic transverse wave oblique probe, and effectively solves the problems in the background technology.
The technical scheme of the invention is as follows: a nondestructive testing method for internal defects of an engine crankshaft comprises the following steps: (1) cleaning the surface of a crankshaft; (2) Selecting a proper ultrasonic transverse wave inclined probe according to the size of the shaft diameter of the crankshaft; (3) Polishing the ultrasonic transverse wave inclined probe according to the diameter radian of the shaft diameter until the probe is completely attached to the surface of the radian of the shaft diameter; (4) debugging the ultrasonic transverse wave inclined probe; (5) Scanning the journal of the crankshaft and the arc position of the R angle by using an ultrasonic transverse wave oblique probe; (6) judging the defects to be detected on the surface and the near surface of the crankshaft; (7) Selecting a proper ultrasonic longitudinal wave straight probe according to the size of the shaft diameter of the crankshaft; (8) Polishing the ultrasonic longitudinal wave straight probe according to the diameter radian of the shaft diameter until the probe is completely attached to the surface of the radian of the shaft diameter; (9) debugging the ultrasonic longitudinal wave straight probe; (10) Scanning the shaft diameter of the crankshaft by using an ultrasonic longitudinal wave straight probe; and (11) judging the defects to be detected in the crankshaft.
The roughness of the surface of the crankshaft is maintained to be less than or equal to 6.3um.
The debugging comprises detection of sound velocity, zero offset and K value and production of DAC curves.
The scanning mode is circumferential zigzag scanning.
In the step (3), the ultrasonic transverse wave inclined probe protective film is subjected to polishing radian treatment to be tightly attached to the crankshaft journal, and two corners of the front edge of the probe are lightly polished to prevent scratches on the surface of the crankshaft in the probe scanning process, so that the defects of the crankshaft diameter, the R-angle surface and the near-surface can be detected.
In the step (6), the determination of the defects to be detected on the surface and the near surface of the crankshaft is performed on the defects to be detected with equivalent sizes of more than 1mm on the surface and the near surface of the crankshaft.
In the step (8), the ultrasonic longitudinal wave straight probe protective film is subjected to polishing radian treatment so as to be closely attached to the shaft diameter of the crankshaft, and two corners of the front edge of the probe are lightly polished, so that scratches on the surface of the crankshaft in the probe scanning process are prevented, and the internal defects of the shaft diameter and the R angle of the crankshaft can be detected.
In the step (11), the determination of the defect to be detected in the crankshaft is the determination of the defect to be detected with the equivalent size of more than 1mm in the crankshaft.
The scanned coupling agent is engine oil.
The scanning speed is maintained to be v less than or equal to 120mm/s.
The beneficial effects of the invention are as follows: the ultrasonic longitudinal wave straight probe and the ultrasonic transverse wave oblique probe are combined to detect the defects of the crankshaft, so that the operation is simple and easy, the use and maintenance cost is low, and the defects of the surface, the near surface and the inside of the diameter and the R angle of the crankshaft can be comprehensively detected.
Drawings
FIG. 1 is a schematic illustration of the detection of the present invention;
FIG. 2 is a view in the direction A of FIG. 1;
FIG. 3 is a view in the B direction of FIG. 1;
FIG. 4 is a view showing the R-angle surface defect of the crankshaft of example No. 2 of the present invention;
FIG. 5 is a surface defect of a diameter of a crankshaft of example No. 2 of the present invention;
FIG. 6 is a 1.2mm defect under the R-angle of the inventive example number 3 crankshaft;
FIG. 7 is a view showing the R-angle surface defect of the crankshaft of example No. 7 of the present invention;
FIG. 8 is a chart showing the axial diameter subcutaneous defect of the number 8 crankshaft of the present invention;
FIG. 9 is a near-core defect of the inventive example number 10 crankshaft;
in the figure: an ultrasonic longitudinal wave straight probe 1, a crankshaft internal defect 2, an ultrasonic transverse wave oblique probe 3, a crankshaft R fillet surface and near surface defect 4, a crankshaft shaft diameter surface and near surface defect 5 and a crankshaft 6.
Description of the embodiments
In order to make the objects, technical solutions and advantages of the embodiments of the present invention more clear, 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, and it is apparent that the described embodiments are a small part of the embodiments of the present invention, but not all embodiments, and all other embodiments obtained by those skilled in the art without making creative efforts based on the embodiments of the present invention are included in the protection scope of the present invention.
A nondestructive testing method for internal defects of an engine crankshaft comprises the following steps: (1) cleaning the surface of a crankshaft; (2) Selecting a proper ultrasonic transverse wave inclined probe according to the size of the shaft diameter of the crankshaft; (3) Polishing the ultrasonic transverse wave inclined probe according to the diameter radian of the shaft diameter until the probe is completely attached to the surface of the radian of the shaft diameter; (4) debugging the ultrasonic transverse wave inclined probe; (5) Scanning the journal of the crankshaft and the arc position of the R angle by using an ultrasonic transverse wave oblique probe; (6) judging the defects to be detected on the surface and the near surface of the crankshaft; (7) Selecting a proper ultrasonic longitudinal wave straight probe according to the size of the shaft diameter of the crankshaft; (8) Polishing the ultrasonic longitudinal wave straight probe according to the diameter radian of the shaft diameter until the probe is completely attached to the surface of the radian of the shaft diameter; (9) debugging the ultrasonic longitudinal wave straight probe; (10) Scanning the shaft diameter of the crankshaft by using an ultrasonic longitudinal wave straight probe; and (11) judging the defects to be detected in the crankshaft.
The roughness of the surface of the crankshaft is maintained to be less than or equal to 6.3um.
The debugging comprises detection of sound velocity, zero offset and K value and production of DAC curves.
The scanning mode is circumferential zigzag scanning.
In the step (3), the ultrasonic transverse wave inclined probe protective film is subjected to polishing radian treatment to be tightly attached to the crankshaft journal, and two corners of the front edge of the probe are lightly polished to prevent scratches on the surface of the crankshaft in the probe scanning process, so that the defects of the crankshaft diameter, the R-angle surface and the near-surface can be detected.
In the step (6), the determination of the defects to be detected on the surface and the near surface of the crankshaft is performed on the defects to be detected with equivalent sizes of more than 1mm on the surface and the near surface of the crankshaft.
In the step (8), the ultrasonic longitudinal wave straight probe protective film is subjected to polishing radian treatment so as to be closely attached to the shaft diameter of the crankshaft, and two corners of the front edge of the probe are lightly polished, so that scratches on the surface of the crankshaft in the probe scanning process are prevented, and the internal defects of the shaft diameter and the R angle of the crankshaft can be detected.
In the step (11), the determination of the defect to be detected in the crankshaft is the determination of the defect to be detected with the equivalent size of more than 1mm in the crankshaft.
The scanned coupling agent is engine oil.
The scanning speed is maintained to be v less than or equal to 120mm/s.
In practical applications, the steps of the nondestructive testing method of the present invention will be described in further detail.
The first step: ultrasonic transverse wave inclined probe detection:
(1) Cleaning the surface of the crankshaft 6 to be detected, and maintaining the surface roughness Ra less than or equal to 6.3um;
(2) Selecting a probe and a wedge block, and selecting a corresponding wedge block according to crankshafts with different specifications in production practice, wherein the ultrasonic transverse wave inclined probe 3 is a probe with the specification of 5P10 multiplied by 12K 1;
(3) Because the detection surface of the crankshaft journal is a curved surface, in order to ensure good coupling, firstly, the protection film of the ultrasonic transverse wave inclined probe 3 is subjected to polishing radian treatment, so that the probe is ensured to be completely attached to the radial cambered surface of the crankshaft journal; in addition, the two angles of the inclined probe cable opposite to the probe are lightly polished, so that the surface of the crankshaft is prevented from being scratched in the scanning process of the probe, and the defects of the diameter of the crankshaft, the arc surface of the R angle and the near surface of the crankshaft can be detected;
(4) Debugging the ultrasonic transverse wave inclined probe 3, including sound velocity, zero offset, detection of K value and manufacturing of DAC curve;
(5) The ultrasonic transverse wave oblique probe 3 is used for carrying out transverse wave scanning on the R-angle, the R-fillet surface and the near-surface defect 4 of the crankshaft and the shaft diameter surface and the near-surface defect 5 of the crankshaft with equivalent sizes of more than 1mm, and scanning positions comprise the journal of the crankshaft 6 and the R-angle arc; the scanning adopts circumferential zigzag scanning, and a coupling agent used for scanning is engine oil; the scanning speed is maintained to be v less than or equal to 120mm/s;
(6) The determination of surface and near-surface defects in the crankshaft 6 is generally performed with reference to GB/T4162;
(7) Selecting an ultrasonic longitudinal wave straight probe 1 with the probe model of 5P20Z according to the shaft diameter of a crankshaft 6;
(8) In order to ensure good coupling, firstly, polishing radian treatment is carried out on a protective film of the ultrasonic longitudinal wave straight probe 1 to ensure that the probe is completely attached to the shaft diameter cambered surface of the crankshaft; in addition, the two angles of the probe opposite to the cable of the oblique probe are lightly polished, so that the surface of the crankshaft is prevented from being scratched in the scanning process of the probe, and the internal defect of the diameter of the crankshaft can be detected;
(9) Debugging the ultrasonic longitudinal wave straight probe 1, detecting sound velocity and zero offset and sensitivity in the debugging process, and manufacturing an AVG curve;
(10) After debugging, the ultrasonic longitudinal wave straight probe 1 is used for scanning, the couplant used for scanning is engine oil, the scanning speed is maintained to be v less than or equal to 120mm/s, and the scanning mode is adopted for scanning in a circumferential zigzag manner, so that the defects of deeper distribution in the crankshaft are mainly overcome.
(11) The determination of internal defects in the crankshaft 6 is generally performed with reference to GB/T4162.
Examples
According to the specific steps of the invention, 10 crankshafts of a certain model are detected, and the detection results are as follows:
and (3) carrying out linear cutting on the detected defective crankshaft at the defect position to obtain a metallographic specimen, verifying the accuracy of ultrasonic flaw detection by metallographic detection, and finding out the defect with the equivalent size at the defect position displayed by ultrasonic flaw detection.
Claims (10)
1. A nondestructive testing method for internal defects of an engine crankshaft is characterized by comprising the following steps: (1) cleaning the surface of a crankshaft; (2) Selecting a proper ultrasonic transverse wave inclined probe according to the size of the shaft diameter of the crankshaft; (3) Polishing the ultrasonic transverse wave inclined probe according to the diameter radian of the shaft diameter until the probe is completely attached to the surface of the radian of the shaft diameter; (4) debugging the ultrasonic transverse wave inclined probe; (5) Scanning the journal of the crankshaft and the arc position of the R angle by using an ultrasonic transverse wave oblique probe; (6) judging the defects to be detected on the surface and the near surface of the crankshaft; (7) Selecting a proper ultrasonic longitudinal wave straight probe according to the size of the shaft diameter of the crankshaft; (8) Polishing the ultrasonic longitudinal wave straight probe according to the diameter radian of the shaft diameter until the probe is completely attached to the surface of the radian of the shaft diameter; (9) debugging the ultrasonic longitudinal wave straight probe; (10) Scanning the shaft diameter of the crankshaft by using an ultrasonic longitudinal wave straight probe; and (11) judging the defects to be detected in the crankshaft.
2. The method for non-destructive inspection of internal defects of an engine crankshaft according to claim 1, wherein: the roughness of the surface of the crankshaft is maintained to be less than or equal to 6.3um.
3. The method for non-destructive inspection of internal defects of an engine crankshaft according to claim 1, wherein: the debugging comprises detection of sound velocity, zero offset and K value and production of DAC curves.
4. The method for non-destructive inspection of internal defects of an engine crankshaft according to claim 1, wherein: the scanning mode is circumferential zigzag scanning.
5. The method for non-destructive inspection of internal defects of an engine crankshaft according to claim 1, wherein: in the step (3), the ultrasonic transverse wave inclined probe protective film is subjected to polishing radian treatment to be tightly attached to the crankshaft journal, and two corners of the front edge of the probe are lightly polished to prevent scratches on the surface of the crankshaft in the probe scanning process, so that the defects of the crankshaft diameter, the R-angle surface and the near-surface can be detected.
6. The method for non-destructive inspection of internal defects of an engine crankshaft according to claim 1, wherein: in the step (6), the determination of the defects to be detected on the surface and the near surface of the crankshaft is performed on the defects to be detected with equivalent sizes of more than 1mm on the surface and the near surface of the crankshaft.
7. The method for non-destructive inspection of internal defects of an engine crankshaft according to claim 1, wherein: in the step (8), the ultrasonic longitudinal wave straight probe protective film is subjected to polishing radian treatment so as to be closely attached to the shaft diameter of the crankshaft, and two corners of the front edge of the probe are lightly polished, so that scratches on the surface of the crankshaft in the probe scanning process are prevented, and the internal defects of the shaft diameter and the R angle of the crankshaft can be detected.
8. The method for non-destructive inspection of internal defects of an engine crankshaft according to claim 1, wherein: in the step (11), the determination of the defect to be detected in the crankshaft is the determination of the defect to be detected with the equivalent size of more than 1mm in the crankshaft.
9. The method for non-destructive inspection of internal defects of an engine crankshaft according to claim 1, wherein: the scanned coupling agent is engine oil.
10. The method for non-destructive inspection of internal defects of an engine crankshaft according to claim 1, wherein: the scanning speed is maintained to be v less than or equal to 120mm/s.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311488101.3A CN117723629A (en) | 2023-11-09 | 2023-11-09 | Nondestructive testing method for internal defects of engine crankshaft |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311488101.3A CN117723629A (en) | 2023-11-09 | 2023-11-09 | Nondestructive testing method for internal defects of engine crankshaft |
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| Publication Number | Publication Date |
|---|---|
| CN117723629A true CN117723629A (en) | 2024-03-19 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202311488101.3A Pending CN117723629A (en) | 2023-11-09 | 2023-11-09 | Nondestructive testing method for internal defects of engine crankshaft |
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| Country | Link |
|---|---|
| CN (1) | CN117723629A (en) |
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2023
- 2023-11-09 CN CN202311488101.3A patent/CN117723629A/en active Pending
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