Comprehensive evaluation method for robustness of ultrasonic 3D automatic scanning of composite materials

Abstract

The present invention relates to the technical field of nondestructive testing, and in particular to a comprehensive evaluation method for the robustness of ultrasonic three-dimensional automatic scanning of composite materials. It includes the following steps: selecting a suitable evaluation piece; preparing evaluation defects; testing the evaluation piece; calculating the robustness of the evaluation piece; evaluating the detected defects; evaluating the robustness of the evaluation piece; and archiving and storing. It fully considers the characteristics of ultrasonic three-dimensional automatic scanning and detection of large composite structures and complex composite structures, the probability of defect detection, and all the characteristics of the actual tested parts. It does not need to separately prepare defect samples for ultrasonic 3D automatic scanning and detection of large and complex composite structures. It can perform ultrasonic C-scan robustness evaluation, and can fully reflect the influence of materials, processes and structural characteristics of large and complex composite structures on ultrasonic 3D scanning detection results. The evaluation cost is low, the cycle is short, the evaluation efficiency is extremely high, the labor intensity is extremely low, and it is environmentally friendly.

Description

Technical Field

[0001] The invention relates to the technical field of nondestructive testing, and in particular to a comprehensive evaluation method for robustness of three-dimensional ultrasonic automatic scanning of composite materials. Background Art

[0002] Large composite structures and complex composite structures are currently widely used in many industrial fields. They are very important composite parts with very high quality, cost, safety and performance requirements. In order to ensure the quality of such critical composite structures, ultrasonic C-scanning is usually required to perform 100% non-destructive testing on them. In order to ensure that the ultrasonic C-scanning obtains correct test results, it is necessary to verify the ultrasonic C-scanning test equipment capabilities and the correctness of the ultrasonic C-scanning test process parameters to obtain robust ultrasonic C-scanning results for evaluating the internal quality of large composite structures and complex composite structures. In order to evaluate the influence of different ultrasonic C-scanning test equipment, test personnel, test processes and test parameters on the test results, the current method is mainly to design and prepare composite comparison test blocks with known defects, and comprehensively judge the correctness and detectability of the ultrasonic C-scanning test results through ultrasonic C-scanning of the comparison test blocks. Therefore, the difference between the comparison test blocks and the actual tested composite parts directly affects the detectability of ultrasonic C-scanning and the correctness of the test results.

[0003] At present, when conducting ultrasonic C-scan testing of composite materials, it is usually necessary to prepare defective comparison test blocks based on the material, process, and structural characteristics of the composite structure being tested, in order to evaluate the rationality and correctness of the selected ultrasonic C-scan equipment, process, and testing parameters. The existing defective test specimens and their defect simulation methods select materials and processes consistent with the composite parts being tested, manufacture typical simple-shaped small-sized defect test blocks, and place thin film simulated defects at different positions inside the defective test blocks as ultrasonic C-scan test comparison test blocks. The significant shortcomings of these test blocks are: (1) Typical simple-shaped small-sized comparison test blocks cannot reflect the geometric characteristics and process characteristics of large composite structures and complex composite structures, thereby affecting the defect detection capability and detection efficiency of ultrasonic C-scanning. (1) The accuracy and adaptability of the test results can be truly evaluated; (2) For large composite structures and complex composite structures, it is difficult to reflect the characteristics of actual composite parts through typical simple shape small-size comparison test blocks, which in turn affects the judgment of the effectiveness and correctness of ultrasonic C-scan detection; (3) In the preparation process of traditional typical simple shape small-size defect test blocks, the material used to simulate the defect needs to be placed inside the sample, which requires a certain production cycle, manufacturing cost, poor defect visualization effect, and is prone to errors beyond expectations. It is difficult to be used for the evaluation of the robustness of ultrasonic three-dimensional automatic scanning detection results of large composite structures and complex composite structures; (4) The defect detection probability and the global difference between the comparison test block and the tested part are not considered at the same time. As an improvement to the evaluation of the ultrasonic C-scan detection effect based on typical simple shape small-size defect comparison test blocks, there is also a defect simulation method of attaching acoustic attenuation materials to the surface of the tested part. Its main shortcomings are: the defect simulation method of external acoustic attenuation materials currently used does not fully consider the process characteristics, structural complexity and ultrasonic C-scanning process of the inspected parts, as well as the requirements for defect detection probability and confidence, and does not provide an evaluation method for the robustness of ultrasonic three-dimensional automatic scanning of large composite structures and complex composite structures, which affects the evaluation of the comprehensive effect of ultrasonic three-dimensional automatic scanning detection and the correctness of the detection results, and further affects the reliability of ultrasonic C-scan detection. As an improvement in the defect detection probability, some comparison test blocks have also introduced a method to reflect the defect detection probability, but its main shortcoming is that there is no evaluation method for the robustness of ultrasonic three-dimensional automatic C-scanning of large composite structures and complex composite structures. Summary of the invention

[0004] 1. Technical issues to be resolved

[0005] The embodiment of the present invention provides a comprehensive evaluation method for the robustness of automatic three-dimensional ultrasonic scanning of composite materials, which solves the technical problems of low efficiency and poor detection reliability of ultrasonic C-scanning detection of large composite materials.

[0006] (II) Technical solution

[0007] The embodiment of the present invention proposes a comprehensive evaluation method for the robustness of ultrasonic three-dimensional automatic scanning of composite materials, comprising the steps of: selecting a suitable evaluation piece; preparing evaluation defects, including determining the material, size, position, quantity and laying method of the evaluation defects; testing the evaluation piece; calculating the robustness of the evaluation piece; evaluating the detected defects; evaluating the robustness of the evaluation piece; and archiving and storing, and archiving all results and data after the robustness calculation.

[0008] Furthermore, selecting appropriate evaluation parts includes: selecting composite materials that actually require ultrasonic three-dimensional automatic C-scan detection as evaluation parts, and the evaluation parts include large and complex composite material structural parts with different resin matrices, different composite material molding processes, and different structural types.

[0009] Furthermore, determining the material for evaluating the defect includes: selecting a film that does not pollute the surface of the inspected composite material piece and is easily attached to the surface thereof as the material for preparing the evaluation defect.

[0010] Further, determining the size of the evaluation defect includes: determining the size of the evaluation defect according to the quality control and inspection requirements of the inspected composite material part

[0011] Further, determining the location of the evaluation defect includes: selecting the external attachment location of the evaluation defect according to the material, process and geometric structure characteristics of the large and complex composite material structure to be inspected, so that each different characteristic part of the composite material structure to be inspected is distributed with a corresponding external attachment defect, and the external attachment defects are distributed on the left and right surfaces of the composite material structure to be inspected, and there is no overlap in the thickness direction, wherein N i represents the number of external defects distributed on the left surface of the inspected composite material, i = 1, 2, ..., n, n is the maximum number of external defects on the left surface, M j represents the number of external defects distributed on the right side surface of the composite material being tested, j = 1, 2, ..., m, where m is the maximum number of external defects on the right side surface, and is selected according to the actual situation of the composite material being tested: N n =M m or N n ≠M m .

[0012] Further, determining the number of evaluation defects includes: determining the number of external defects according to the confidence level and the defect detection probability, and the calculation formula is: N n +M m ≥N p , where N pIt is the minimum number of defects under given ultrasonic C-scan defect detection confidence CL and detection probability POD conditions, determined by the quality control and inspection requirements of the inspected composite material parts.

[0013] Furthermore, determining a paving method for evaluating defects includes: according to the determined defect positions and defect quantities, respectively paving defects of selected sizes on the left and right surfaces of the inspected composite material component.

[0014] Furthermore, testing the evaluation piece includes: using the same ultrasonic three-dimensional automatic C-scanning testing conditions, testing the prepared evaluation piece three times respectively, and saving each test result.

[0015] Furthermore, calculating the robustness of the evaluation part includes: evaluating the three ultrasonic three-dimensional automatic C-scan results of the evaluation part, and calculating the number of detected defects M in the three ultrasonic three-dimensional automatic C-scan results. d , the formula for calculating robustness is:

[0016] Furthermore, the evaluation of the detected defects includes: evaluating the number of actual detected defects based on the ultrasonic C-scan detection results when The defect is judged to be effectively detected; when It is determined that the defect cannot be detected.

[0017] (III) Beneficial effects

[0018] In summary, the present invention fully considers the ultrasonic three-dimensional automatic scanning detection characteristics and defect detection probability of large-scale composite structures and complex composite structures as well as all the characteristics of the actual inspected parts. It does not need to separately prepare defect samples for ultrasonic 3D automatic scanning detection of large-scale and complex composite structures, and can perform ultrasonic C-scan robustness evaluation. It can also fully reflect the influence of materials, processes and structural characteristics of large-scale and complex composite structures on ultrasonic 3D scanning detection results. The evaluation cost is low, the cycle is short, the evaluation efficiency is extremely high, the labor intensity is extremely low, and it is environmentally friendly. It can also better evaluate the effectiveness and correctness of the ultrasonic 3D automatic scanning detection results of large-scale and complex composite structures, ensure the robustness of the ultrasonic 3D automatic scanning detection results of large-scale and complex composite structures, and thus help to improve the accuracy and reliability of the ultrasonic automatic scanning detection results of large-scale and complex composite structures. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments of the present invention are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0020] Figure 1 It is a flow chart of a comprehensive evaluation method for robustness of automatic ultrasonic three-dimensional scanning of composite materials according to an embodiment of the present invention;

[0021] Figure 2 It is a schematic diagram of a composite material part to be inspected and its defect distribution in a comprehensive evaluation method for robustness of composite material ultrasonic three-dimensional automatic scanning according to an embodiment of the present invention;

[0022] In the figure: 1, inspected composite material part; 1A, left side surface; 1B, right side surface. DETAILED DESCRIPTION

[0023] The following is a further detailed description of the embodiments of the present invention in conjunction with the accompanying drawings and examples. The detailed description of the following embodiments and the accompanying drawings are used to exemplarily illustrate the principles of the present invention, but cannot be used to limit the scope of the present invention, that is, the present invention is not limited to the described embodiments, and covers any modification, replacement and improvement of parts, components and connection modes without departing from the spirit of the present invention.

[0024] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application can be combined with each other. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0025] Please refer to Figure 1The embodiment of the present invention proposes a comprehensive evaluation method for the robustness of composite materials ultrasonic three-dimensional automatic scanning, including the steps of: selecting a suitable evaluation piece; preparing evaluation defects, including determining the material, size, position, quantity and paving method of the evaluation defects; testing the evaluation piece; calculating the robustness of the evaluation piece; evaluating the detected defects; evaluating the robustness of the evaluation piece; and archiving and storing, and archiving all the results and data after the robustness calculation. The ultrasonic three-dimensional automatic scanning detection characteristics and defect detection probability of large-scale composite structures and complex composite structures as well as all the characteristics of the actual inspected parts are fully considered. There is no need to separately prepare defect samples for ultrasonic 3D automatic scanning detection of large and complex composite structures. Ultrasonic C-scan robustness evaluation can be performed, and the influence of material, process and structural characteristics of large and complex composite structures on ultrasonic 3D scanning detection results can be fully reflected. The evaluation cost is low, the cycle is short, the evaluation efficiency is extremely high, the labor intensity is extremely low, and it is environmentally friendly. It can also better evaluate the effectiveness and correctness of ultrasonic 3D automatic scanning detection results of large and complex composite structures, ensure the robustness of ultrasonic 3D automatic scanning detection results of large and complex composite structures, and thus help to improve the accuracy and reliability of ultrasonic automatic scanning detection results of large and complex composite structures.

[0026] In some embodiments, selecting suitable evaluation parts includes: selecting composite materials that actually require ultrasonic three-dimensional automatic C-scan detection as evaluation parts, and the evaluation parts include large and complex composite structural parts with different resin matrices, different composite molding processes, and different structural types.

[0027] In some embodiments, determining the material for evaluating the defect includes: selecting a thin film that does not pollute the surface of the inspected composite material and is easily attached to the surface as the material for preparing the evaluation defect.

[0028] In some embodiments, determining the size of the evaluation defect includes: determining the size of the evaluation defect according to the quality control and inspection requirements of the inspected composite material part

[0029] Please refer to Figure 2 In some embodiments, determining the location of the evaluation defect includes: selecting the external location of the evaluation defect according to the material, process and geometric structure characteristics of the large and complex composite material structure to be inspected, so that each different characteristic part of the inspected composite material structure is distributed with a corresponding external defect, and the external defects are distributed on the left surface 1A and the right surface 1B of the inspected composite material structure, and there is no overlap in the thickness direction, wherein N i represents the number of external defects distributed on the left side surface 1A of the inspected composite material 1, i=1, 2, ..., n, n is the maximum number of external defects on the left side surface 1A, M jrepresents the number of external defects distributed on the right side surface 1B of the inspected composite material part 1, j = 1, 2, ..., m, where m is the maximum number of external defects on the right side surface 1B, and is selected according to the actual situation of the inspected composite material part 1: N n =M m or N n ≠M m .

[0030] In some embodiments, determining the number of evaluation defects includes: determining the number of external defects according to the confidence level and the defect detection probability, and the calculation formula is: N n +M m ≥N p , where N p It is the minimum number of defects under given ultrasonic C-scan defect detection confidence CL and detection probability POD conditions, and is determined by the quality control and inspection requirements of the inspected composite material part 1.

[0031] In some embodiments, determining the paving method for evaluating defects includes: according to the determined defect positions and defect quantities, respectively attaching defects of selected sizes to the left surface 1A and the right surface 1B of the inspected composite material member 1 .

[0032] In some embodiments, testing the evaluation piece includes: using the same ultrasonic three-dimensional automatic C-scanning testing conditions, testing the prepared evaluation piece three times respectively, and saving each test result.

[0033] In some embodiments, calculating the robustness of the evaluation part includes: evaluating the three ultrasonic three-dimensional automatic C-scan results of the evaluation part, and calculating the number of detected defects M in the three ultrasonic three-dimensional automatic C-scan results. d , the formula for calculating robustness is:

[0034] The evaluation of the robustness of the evaluation document includes:

[0035] (1) When γ≥90%, the comprehensive effect of ultrasonic three-dimensional automatic C-scan detection is evaluated as very robust, defined as grade A.

[0036] (2) When 90%>γ≥80%, the comprehensive effect of ultrasonic three-dimensional automatic C-scan detection was evaluated as robust and defined as grade B.

[0037] (3) When γ<80%, the comprehensive effect of ultrasonic three-dimensional automatic C-scan detection was evaluated as unrobust and defined as grade C.

[0038] When the comprehensive effect of ultrasonic three-dimensional automatic C-scan detection is evaluated as Grade A, it means that the selected ultrasonic C-scan equipment, formulated detection process and parameters are suitable for the detection of such composite parts.

[0039] When the comprehensive effect of ultrasonic three-dimensional automatic C-scan detection is evaluated as Class B, it means that the selected ultrasonic C-scan equipment, formulated detection process and parameters can be used for the detection of such composite parts, but further optimization is still needed.

[0040] When the comprehensive effect of ultrasonic three-dimensional automatic C-scan detection is evaluated as Class C, it means that the selected ultrasonic C-scan equipment, the formulated detection process and parameters are not recommended for the detection of such composite parts, and further improvements are needed before re-evaluation of robustness.

[0041] In some embodiments, evaluating the detected defects includes: evaluating the number of actual detected defects based on the ultrasonic C-scan detection results. when The defect is judged to be effectively detected; when It is determined that the defect cannot be detected.

[0042] Example:

[0043] We selected 3200mm×1600mm large composite wall panels and 1300mm×600mm complex composite parts respectively. 6mm,N n =42,M m =48,N p =73, after 3 ultrasound C scans, 6mm two kinds of defects, the number of defects detected is M d =290, and the robustness is γ=100%. The test results show that the method can be used to efficiently and accurately evaluate the comprehensive detection effect of composite materials by ultrasonic three-dimensional automatic C-scanning. There is no need to prepare special evaluation samples. The cost is very low, the evaluation cycle is very short, the evaluation efficiency is high, the labor intensity is extremely low, it is non-toxic and environmentally friendly, and it can better evaluate the effectiveness and correctness of the composite materials ultrasonic three-dimensional automatic C-scanning detection results, which is more conducive to improving the accuracy and reliability of ultrasonic C-scanning detection results.

[0044] It should be clear that the various embodiments in this specification are described in a progressive manner, and the same or similar parts between the various embodiments can be referred to each other, and each embodiment focuses on the differences from other embodiments. The present invention is not limited to the specific steps and structures described above and shown in the figures. In addition, for the sake of brevity, a detailed description of known methods and technologies is omitted here.

[0045] The above is only an embodiment of the present application and is not limited to the present application. For those skilled in the art, the present application may have various changes and variations without departing from the scope of the present invention. Any modification, equivalent substitution, improvement, etc. made within the spirit and principle of the present application should be included in the scope of the claims of the present application.

Claims

1. A comprehensive evaluation method for the robustness of ultrasonic three-dimensional automatic scanning of composite materials, characterized in that: Includes steps: Select appropriate evaluation parts, including composite parts that are actually required to undergo ultrasonic three-dimensional automatic C-scan testing as evaluation parts. The evaluation parts include large and complex composite structural parts with different resin matrices, different composite molding processes, and different structural types. Preparation of evaluation defects, including determining the material, size, position, quantity and laying method of the evaluation defects, selecting a film that does not pollute the surface of the inspected composite material and is easy to be attached to the surface as the material for preparing the evaluation defects, determining the size of the evaluation defects according to the quality control and inspection requirements of the inspected composite material, selecting the external attachment position of the evaluation defects according to the material, process and geometric structure characteristics of the inspected large and complex composite structure, so that each different characteristic part of the inspected composite structure is distributed with a corresponding external attachment defect, and the external attachment defects are distributed on the left and right surfaces of the inspected composite structure, and there is no overlap in the thickness direction, wherein N i represents the number of external defects distributed on the left surface of the inspected composite material, i = 1, 2, ..., n, n is the maximum number of external defects on the left surface, M j represents the number of external defects distributed on the right side surface of the composite material being tested, j = 1, 2, ..., m, where m is the maximum number of external defects on the right side surface, and is selected according to the actual situation of the composite material being tested: N n =M m or N n ≠M m , the number of external defects is determined according to the confidence level and defect detection probability, and the calculation formula is: N n +M m ≥N p , where N p The minimum number of defects under the given ultrasonic C-scan defect detection confidence CL and detection probability POD conditions is determined by the quality control and inspection requirements of the inspected composite material part. According to the determined defect positions and defect quantities, defects of selected sizes are respectively attached to the left and right surfaces of the inspected composite material part. Testing the evaluation parts, including testing the prepared evaluation parts three times using the same ultrasonic three-dimensional automatic C-scan testing conditions, and saving the test results of each time; Calculate the robustness of the evaluation part, including evaluating the three ultrasonic three-dimensional automatic C-scan results of the evaluation part, and finding the number of detected defects M in the three ultrasonic three-dimensional automatic C-scan results d , the formula for calculating robustness is: 00%； Evaluation of detected defects, including evaluation of the actual number of detected defects based on ultrasonic C-scan detection results ,when , it is determined that the defect is effectively detected; when , it is determined that the defect cannot be detected; Evaluate the robustness of the evaluation items; Create files and save them to archive all the results and data after robustness calculation.

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