CN1793899A - Regulating method of mill roll surface wave detection sensitivity - Google Patents
Regulating method of mill roll surface wave detection sensitivity Download PDFInfo
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- CN1793899A CN1793899A CN 200510111865 CN200510111865A CN1793899A CN 1793899 A CN1793899 A CN 1793899A CN 200510111865 CN200510111865 CN 200510111865 CN 200510111865 A CN200510111865 A CN 200510111865A CN 1793899 A CN1793899 A CN 1793899A
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Abstract
A method for regulating sensitivity of roller surface wave detection includes establishing function relation of various factors influencing detection sensitivity and using right angle edge of roller body as infinite long and infinite deep crack then defining mathematical model on ratio of wave height reflected by said edge to wave height reflected by finite long and finite deep crack as well as ratio of wave height reflected by crack in the same length and different depth to wave height reflected by 0.17 deep crack, applying calculation and comparison on actually measured data to achieve purpose of accurate quantization measurement.
Description
Affiliated technical field
Regulating method of mill roll surface wave detection sensitivity of the present invention relates to a kind of roller type work-piece lossless detection method.
Background technology
Roll roller kind has cold roll, high-speed steel working roll (hot rolling), indefinite chill working roll (hot rolling), R2 working roll, and its material is divided into forged steel, high-speed steel, cast iron.For the roller type work-piece surface defects detection, before the application surface wave technology, our breaker roll detects and adopts traditional detection method: magnetic detects, infiltration detects and EDDY CURRENT.Magnetic, infiltration detect and can't realize industrial automation, and all adopt the visual method check, and efficient is low, and it is inevitable to judge by accident, fail to judge; The EDDY CURRENT false signal is many, is difficult for distinguishing and confirming defective.
Japan is Application and Development surface wave technology, regulates method but only limit to test block aspect sensitivity adjusting, and defects detecting technology also more complicated, detection efficiency is lower, is unsuitable for using at Baosteel.Other countries also do not have relevant data to announce.
Summary of the invention
The object of the present invention is to provide a kind of regulating method of mill roll surface wave detection sensitivity,, reach the purpose of accurate measures of quantization by establishing mathematical model.
Purpose of the present invention realizes by following proposal: a kind of regulating method of mill roll surface wave detection sensitivity, establish the funtcional relationship between each factor that influences detection sensitivity, wherein, regard the rectangular edge of roll barrel as endless and unlimited dark crackle, wave height and the ratio that limit for length, limited deep-fissured reflection wave wave height are arranged for roll rectangular edge reflection wave, and equal length, the ratio defined formula of the crack deflection wave-wave height that the reflection wave wave height of different depth crackle and 0.17 λ are dark is as follows:
HB/Hf＝[πx/2Ln]
0.5·∫
0 2(e
-a·z/λ-b’e
-c·z/λ)d(z/λ)/∫
0 n[(e
-a·z/λ-b’e
-c·z/λ)d(z/λ)]
0.5
In the formula: HB-rectangular edge reflection wave wave height;
Hf-crack deflection wave-wave height;
The minimum crack length that the L-desire is surveyed;
The minimum crack depth d that the n-desire is surveyed and the ratio of wavelength X: i.e. d/ λ;
The X-reflecting body is to the distance of sound source;
A, b, c-is relevant with the medium elastic property, is decided by the constant of Poisson ratio σ;
Z-is apart from the degree of depth on surface;
For high-speed steel working roll, indefinite chill working roll, R
2Working roll when adopting surface wave probe frequency f=1MHz, can get HB/Hf=37.43, is equivalent to 31dB, means that then the minimum-depth scope that frequency of utilization f=1MHz surface wave probe can accurately detect surface imperfection is in 0.17 * 2.9=0.49mm; Adopt surface wave probe frequency f=2MHz to detect the high-speed steel working roll, can get HB/Hf=37.4, also be equivalent to 31dB, then can accurately detect surface imperfection the minimum-depth scope be 0.17 * 1.45=0.245mm.
On the such scheme basis, described regulating method of mill roll surface wave detection sensitivity: directly on roll, adjust base line, carry out the adjusting of sensitivity then: mobile probe, at distance 100～1000 millimeters places of end face, intact sunken roll right angle, make the surface wave propagation direction perpendicular to roll right angle end face, make end surface edge reflection wave wave height reach altitude datum, be all over the screen 20%～50%, the dB of gain regulation again number, simultaneously careless shape ripple is controlled at and is not more than 10%, to unappeasable, reduce by the dB number of 2～3dB.
Wherein, base line adjustment system directly adjusts on roll.To pop one's head in earlier and vertically aim at the seamed edge of roll right angle end face, open automatic correction menu if adopt digital instrument this moment, makes seamed edge apart from probe forward position 40mm, occurs the reflection wave (position I) of seamed edge on the video screen, and instrument settings 1 is 40mm.Mobile again gate makes seamed edge apart from probe forward position 65mm in the reflection wave place, occurs the reflection wave (position II) of seamed edge on the video screen, and the value of setting 2 is 65mm, and mobile gate is in the reflection wave place, and carriage return confirms that the adjustment of oscillography this moment screen base line finishes.
For the roller surface defect degree of depth quantitatively and depth of defect less than the defective of 2 λ, according to following formula:
Hf/H
0.17＝7.487n
0.5[∫
0 n(e
-a·z/λ-b’e
-c·z/λ)
2d(z/λ)]
0.5
Make wave height, the relation curve of dB number and depth of defect promptly gains, with defect length L=6.5mm, manual simulation's crack defect test block of depth d=0.25～3.5mm is a benchmark, uses the f=2MHz surface wave probe, calculates and draws through test-data acquisition, under the sensitivity condition of setting, when being higher than the defect waves of benchmark wave height, the dB that obtains itself and benchmark wave height is poor, estimates the size and the order of severity of defective.
During on-the-spot the detection, directly on roll, adjust base line, carry out the adjusting of sensitivity then: mobile probe, apart from end face 500mm place, intact sunken roll right angle, make the surface wave propagation direction perpendicular to end face, make the high benchmark height (all over the screen 20%～50%) that arrives of end face reflection wave-wave, the dB of gain regulation again number, simultaneously careless shape ripple is controlled at below 10%,, must reduces certain dB number (general 2～3dB) as not satisfying.In actual detected,, generally reduce certain dB number and can satisfy careless shape ripple and be controlled at requirement below 10% as hot rolling working roll, indefinite chill roller.
Make the relation curve of wave height (gain dB number) and depth of defect, shown in the relation curve of following Fig. 1 wave height and depth of defect: this figure is with defect length L=6.5mm, manual simulation's crack defect test block of depth d=0.25～3.5mm is a benchmark, use the f=2MHz surface wave probe, through test-data acquisition calculating and curve plotting.As the case may be, need to carry out the necessary parameter correction sometimes during on-the-spot the detection.
During roll detects, carry out scanning under the sensitivity of regulation, the long little defective of 1mm can omission yet.Under the sensitivity condition of setting, find to be higher than the defect waves of benchmark wave height, the dB that obtains itself and benchmark wave height is poor, can roughly estimate size, the order of severity of defective.In conjunction with the crack detection result, comparison roll dressing removal amount finds that both comparatively conform to.
For the hot rolling working roll, about its grain size M12, mean diameter d=0.55mm, with wavelength X at the same order of magnitude, major influence factors shows as frequency f and coefficient of anisotropy F.Adopt the cold roll of Ladle Refining Ingot as cold rolling blank forging, its grain size number is about 8 grades, mean diameter d=0.022mm.With respect to f=1MHz, λ=c/f=2.9mm (c: surperficial velocity of wave 2900m/s), f=2MHz, λ=c/f=1.45mm, roll crystal grain diameter d＜＜λ.According to the diffraction principle of Huygens and Bo as can be known, the diffraction of ripple is strong, a little less than the reflection.When surface wave detected cold roll, the waveform demonstration adopted the MHz surface wave to detect shown in certain cold roll waveform as Fig. 2, does not have any careless shape ripple.The hot rolling working roll, about its grain size M12, mean diameter d=0.55mm, with wavelength X at the same order of magnitude, major influence factors shows as frequency and coefficient of anisotropy F.
Coarse grain is also influential to detecting: shown in the grass shape waveform, when Fig. 4 adopts the 4MHz double-crystal normal probe to detect the roll working lining, the crystal grain reflection configuration occurs, at this moment λ=1.5mm when adopting the 1MHz surface wave to detect certain hot roll as Fig. 3.
Practice finds that the factor that influences sensitivity adjusting in the detection mainly contains:
1. the influence of greasy dirt
2. the influence of surfaceness and material structure
3. the influence of curve form
4. the influence of defective locations and shape
5. the influence of distance between defective and the probe.
Superiority of the present invention is: can be according to roll kind, material, grain size, surface appearance, correctly select the surface wave probe of different frequency, the detection sensitivity that adapts, accurately detect the fine crack and other surface imperfection that cause peeling off roll breakage.Can concern chart by the sensitivity influence factor that the contrast experiment sets up quantification.
Description of drawings
The relation curve of Fig. 1 wave height (gain dB number) and depth of defect
Fig. 2 adopts the 2MHz surface wave to detect certain cold roll waveform
Grass shape waveform when Fig. 3 adopts the 1MHz surface wave to detect certain hot roll
The crystal grain reflection configuration appears in Fig. 4 when adopting the 4MHz double-crystal normal probe to detect the roll working lining
Crackle waveform and the magnetic trace of Fig. 5 high-speed steel hot roll surface wave probe 1MHz
Crackle waveform and the magnetic trace of Fig. 6 forged steel roll surface ripple probe 2MHz
Pattern cracking waveform and the magnetic trace of Fig. 7 high-speed steel work roll surface ripple probe 1MHz
Crackle waveform and the magnetic trace of Fig. 8 indefinite chill roller surface wave probe 1MHz
Crackle waveform and the magnetic trace of Fig. 9 forging steel cold roll surface wave probe 2MHz
Embodiment
A kind of regulating method of mill roll surface wave detection sensitivity, establish the funtcional relationship between each factor that influences detection sensitivity, wherein, regard the rectangular edge of roll barrel as endless and unlimited dark crackle, wave height and the ratio that limit for length, limited deep-fissured reflection wave wave height are arranged for roll rectangular edge reflection wave, and equal length, the ratio defined formula of the crack deflection wave-wave height that the reflection wave wave height of different depth crackle and 0.17 λ are dark is as follows:
HB/Hf＝[πx/2Ln]
0.5·
0 2∫(e
-a·z/λ-b’e
-c·z/λ)d(z/λ)/
0 n∫[(e
-a·z/λ-b’e
-c·z/λ)d(z/λ)]
0.5
In the formula: HB-rectangular edge reflection wave wave height;
Hf-crack deflection wave-wave height;
The minimum crack length that the L-desire is surveyed;
The minimum crack depth d that the n-desire is surveyed and the ratio of wavelength X: i.e. d/ λ;
The X-reflecting body is to the distance of sound source;
A, b, c-is relevant with the medium elastic property, is decided by the constant of Poisson ratio σ;
Z-is apart from the degree of depth on surface;
For high-speed steel working roll, indefinite chill working roll, R
2Working roll when adopting surface wave probe frequency f=1MHz, can get HB/Hf=37.43, is equivalent to 31dB, means that then the minimum-depth scope that frequency of utilization f=1MHz surface wave probe can accurately detect surface imperfection is in 0.17 * 2.9=0.49mm; Adopt surface wave probe frequency f=2MHz to detect the high-speed steel working roll, can get HB/Hf=37.4, also be equivalent to 31dB, then can accurately detect surface imperfection the minimum-depth scope be 0.17 * 1.45=0.245mm.
Directly on roll, adjust base line, carry out the adjusting of sensitivity then: mobile probe, at distance 100～1000 millimeters places of end face, intact sunken roll right angle, make the surface wave propagation direction perpendicular to roll right angle end face, make end surface edge reflection wave wave height reach altitude datum, promptly all over the screen 20%～50%, the dB of gain regulation again number, simultaneously careless shape ripple is controlled at and is not more than 10%,, reduce by the dB number of 2～3dB unappeasable.
For the roller surface defect degree of depth quantitatively and depth of defect less than the defective of 2 λ, according to following formula:
Hf/H
0.17=7.487n
0.5[∫
0 n(e
-az/ λ-b ' e
-cz/ λ)
2D (z/ λ)]
0.5Make wave height, the relation curve of dB number and depth of defect promptly gains, with defect length L=6.5mm, manual simulation's crack defect test block of depth d=0.25～3.5mm is a benchmark, uses the f=2MHz surface wave probe, calculates and draws through test-data acquisition, under the sensitivity condition of setting, when being higher than the defect waves of benchmark wave height, the dB that obtains itself and benchmark wave height is poor, estimates the size and the order of severity of defective.
21 days～June 30 January in 2004, detect 1580,2050 high-speed steel working rolls, 2412 rollers altogether at Baosteel hot rolling application surface wave technology, wherein normally descend machine working roll 1700 rollers, normally descend machine to add several 97 rollers of mill.So far a routine spalling of rolls accident do not occur, guaranteed carrying out smoothly of hot rolling mill production, and created the economic benefit of units up to a million for company.
According to the detection sensitivity that our sensitivity adjustment method is determined, can find the surface crack of the 0.125mm degree of depth, can roughly estimate the degree of depth of crackle again according to the reflection wave amplitude.The testing staff is according to roll kind, material, and grain size, surface appearance are correctly selected the surface wave probe of different frequency, the detection sensitivity that adapts, and accurately detects the fine crack and other surface imperfection that cause peeling off roll breakage.
Use sensitivity adjusting technology of the present invention, pattern cracking waveform and magnetic trace, the crackle waveform of Fig. 8 indefinite chill roller surface wave probe 1MHz and crackle waveform and the magnetic trace of magnetic trace and Fig. 9 forging steel cold roll surface wave probe 2MHz of the crackle waveform of the crackle waveform of actual detected defect map and waveform such as Fig. 5 high-speed steel hot roll surface wave probe 1MHz and magnetic trace, Fig. 6 forged steel roll surface ripple probe 2MHz and magnetic trace, Fig. 7 high-speed steel work roll surface ripple probe 1MHz.
Claims (3)
1. regulating method of mill roll surface wave detection sensitivity, establish the funtcional relationship between each factor that influences detection sensitivity, wherein, regard the rectangular edge of roll barrel as endless and unlimited dark crackle, wave height and the ratio that limit for length, limited deep-fissured reflection wave wave height are arranged for roll rectangular edge reflection wave, and equal length, the ratio defined formula of the crack deflection wave-wave height that the reflection wave wave height of different depth crackle and 0.17 λ are dark is as follows:
HB/Hf＝[πx/2Ln]
0.5·
0 2∫(e
-a·z/λ-b’e
-c·z/λ)d?(z/λ)/
0 n∫[(e
-a·z/λ-b’e
-c·z/λ)d(z/λ)]
0.5
In the formula: HB-rectangular edge reflection wave wave height;
Hf-crack deflection wave-wave height;
The minimum crack length that the L-desire is surveyed;
The minimum crack depth d that the n-desire is surveyed and the ratio of wavelength X: i.e. d/ λ;
The X-reflecting body is to the distance of sound source;
A, b, c-is relevant with the medium elastic property, is decided by the constant of Poisson ratio σ;
Z-is apart from the degree of depth on surface;
For high-speed steel working roll, indefinite chill working roll, R
2Working roll when adopting surface wave probe frequency f=1MHz, can get HB/Hf=37.43, is equivalent to 31dB, means that then the minimum-depth scope that frequency of utilization f=1MHz surface wave probe can accurately detect surface imperfection is in 0.17 * 2.9=0.49mm; Adopt surface wave probe frequency f=2MHz to detect the high-speed steel working roll, can get HB/Hf=37.4, also be equivalent to 31dB, then can accurately detect surface imperfection the minimum-depth scope be 0.17 * 1.45=0.245mm.
2. regulating method of mill roll surface wave detection sensitivity according to claim 1, it is characterized in that: directly on roll, adjust base line, carry out the adjusting of sensitivity then: mobile probe, at distance 100～1000 millimeters places of end face, intact sunken roll right angle, make the surface wave propagation direction perpendicular to roll right angle end face, make end surface edge reflection wave wave height reach altitude datum, be all over the screen 20%～50%, the dB of gain regulation again number, simultaneously careless shape ripple is controlled at and is not more than 10%, to unappeasable, reduce by the dB number of 2～3dB.
3. regulating method of mill roll surface wave detection sensitivity according to claim 1 is characterized in that: for the roller surface defect degree of depth quantitatively and depth of defect less than the defective of 2 λ, according to following formula:
Hf/H
0.17=7.487n
0.5[∫
0 n(e
-az/ λ-b ' e
-cz/ λ)
2D (z/ λ)]
0.5Make wave height, the relation curve of dB number and depth of defect promptly gains, with defect length L=6.5mm, manual simulation's crack defect test block of depth d=0.25～3.5mm is a benchmark, uses the f=2MHz surface wave probe, calculates and draws through test-data acquisition, under the sensitivity condition of setting, when being higher than the defect waves of benchmark wave height, the dB that obtains itself and benchmark wave height is poor, estimates the size and the order of severity of defective.
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Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101206195B (en) * | 2006-12-21 | 2010-11-24 | 上海宝钢工业检测公司 | Method for testing burial depth of approximate surface layer defect by ultrasound wave |
| CN102297897A (en) * | 2010-06-25 | 2011-12-28 | 上海宝钢工业检测公司 | Method for adjusting detection sensitivity of roll surface wave |
| CN102016566B (en) * | 2008-03-27 | 2012-09-05 | 住友金属工业株式会社 | Ultrasonic flaw detection method and device |
| CN103868830A (en) * | 2012-12-18 | 2014-06-18 | 上海宝钢工业技术服务有限公司 | Rapid detection evaluation method of roller surface layer grain size |
| CN105842344A (en) * | 2016-03-28 | 2016-08-10 | 深圳市科兰德实业发展有限公司 | Bridge monitoring apparatus and bridge monitoring method |
| CN108414620A (en) * | 2018-03-17 | 2018-08-17 | 北京工业大学 | Path is deep than special-shaped inner wall of the pipe circumferential crack rayleigh waves inspection method |
| CN108519435A (en) * | 2018-05-23 | 2018-09-11 | 上海金艺检测技术有限公司 | The sensitivity adjustment method of roll barrel rayleigh waves inspection |
| CN112525992A (en) * | 2020-11-27 | 2021-03-19 | 宝钢轧辊科技有限责任公司 | Sendzimir roller surface wave flaw detection method |
-
2005
- 2005-12-23 CN CN 200510111865 patent/CN1793899A/en active Pending
Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101206195B (en) * | 2006-12-21 | 2010-11-24 | 上海宝钢工业检测公司 | Method for testing burial depth of approximate surface layer defect by ultrasound wave |
| CN102016566B (en) * | 2008-03-27 | 2012-09-05 | 住友金属工业株式会社 | Ultrasonic flaw detection method and device |
| CN102297897A (en) * | 2010-06-25 | 2011-12-28 | 上海宝钢工业检测公司 | Method for adjusting detection sensitivity of roll surface wave |
| CN103868830A (en) * | 2012-12-18 | 2014-06-18 | 上海宝钢工业技术服务有限公司 | Rapid detection evaluation method of roller surface layer grain size |
| CN105842344A (en) * | 2016-03-28 | 2016-08-10 | 深圳市科兰德实业发展有限公司 | Bridge monitoring apparatus and bridge monitoring method |
| CN108414620A (en) * | 2018-03-17 | 2018-08-17 | 北京工业大学 | Path is deep than special-shaped inner wall of the pipe circumferential crack rayleigh waves inspection method |
| CN108414620B (en) * | 2018-03-17 | 2021-01-05 | 北京工业大学 | Surface wave detection method for circumferential cracks on inner wall of small-diameter depth ratio special-shaped pipeline |
| CN108519435A (en) * | 2018-05-23 | 2018-09-11 | 上海金艺检测技术有限公司 | The sensitivity adjustment method of roll barrel rayleigh waves inspection |
| CN112525992A (en) * | 2020-11-27 | 2021-03-19 | 宝钢轧辊科技有限责任公司 | Sendzimir roller surface wave flaw detection method |
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Open date: 20060628 |