A method for calibrating the transition arc of a railway vehicle axle using ultrasonic shear waves

Abstract

The present invention relates to the technical field of ultrasonic shear wave detection of axles, and specifically to a calibration method for ultrasonic shear wave detection of transition arc parts of railway vehicle axles, comprising a calibration test block with a length dimension of L and a diameter dimension of ф and an ultrasonic shear wave detection probe, wherein the end of the calibration test block is provided with a transverse inclined surface which is X° with the axis of the calibration test block, and three burial depths are vertically drilled on the long axis center line of the transverse inclined surface, namely, a first flat bottom hole, a second flat bottom hole and a third flat bottom hole, wherein the first flat bottom hole, the second flat bottom hole and the third flat bottom hole have a hole depth of Ymm and a hole diameter of фZmm. The present invention realizes ultrasonic shear wave detection of transition arc parts at the step of axle products of railway locomotives and vehicles by making a calibration test block for ultrasonic shear wave detection of transition arc parts at the step of axle products, and also has the advantages of fast detection speed and low detection cost, and at the same time, the test block has an exquisite and compact design structure, which is convenient for operators to operate, simple and practical.

Description

Technical Field

[0001] The invention relates to the technical field of ultrasonic shear wave detection of axles, and in particular to an ultrasonic shear wave detection and calibration method for transition arc parts of axles of railway vehicles. Background Art

[0002] The axle products of railway locomotives and rolling stock are important load-bearing components of the running part of the locomotives and rolling stock. When the locomotives and rolling stock are running on the rails, the axles are prone to fatigue defects under the combined effect of their own load-bearing and the impact force between the wheels and rails. When the axle fails due to fatigue, the load-bearing function of the axle also fails, which seriously affects the efficiency and safety of railway transportation. In general, in order to ensure the reliable operation of locomotives and rolling stock, strict requirements are placed on the intrinsic quality of axle products, so non-destructive testing of internal defects of axle products is also particularly important.

[0003] The testing processes specified in the existing international standards ISO 5948, the North American Association of Railroads standard AAR M101, and my country's railway industry standard TB / T 1618 use ultrasonic longitudinal wave testing methods to conduct testing in the axle diameter direction, which can effectively solve the problem of ultrasonic radial testing of the straight parts of axle products.

[0004] However, due to the shape difference between the longitudinal wave straight probe and the transition arc part at the step of the axle product, the probe and the axle cannot be effectively coupled, resulting in the probe being unable to accurately detect the transition arc part, reducing the detection accuracy.

[0005] Based on this, the present invention designs an ultrasonic shear wave detection calibration test block and method for the transition arc part of a railway vehicle axle to solve the above-mentioned problem. Summary of the invention

[0006] The object of the present invention is to provide an ultrasonic shear wave detection and calibration method for the transition arc part of a railway vehicle axle, so as to solve the problem in the prior art proposed in the above background technology that the transition arc part at the step of the axle product cannot be effectively coupled with the axle due to the shape difference between the longitudinal wave straight probe and the transition arc part, thereby causing the probe to be unable to accurately detect the transition arc part, thereby reducing the detection accuracy.

[0007] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: a method for ultrasonic shear wave detection and calibration of transition arc parts of railway vehicle axles, comprising a calibration test block with a length dimension of L and a diameter dimension of ф and an ultrasonic shear wave detection probe, wherein the end of the calibration test block is provided with a cross-cutting inclined surface with an angle of X° with the axis of the calibration test block, and three burial depths are vertically drilled on the long axis center line of the cross-cutting inclined surface, namely, a first flat bottom hole, a second flat bottom hole and a third flat bottom hole, wherein the first flat bottom hole, the second flat bottom hole and the third flat bottom hole are all Ymm in depth and фZmm in diameter;

[0008] The calibration sound path sizes of the first flat bottom hole, the second flat bottom hole and the third flat bottom hole are L1, L2 and L3 respectively; the distance between the first flat bottom hole and the top of the cross-cutting slope is L4; the distance between the second flat bottom hole and the first flat bottom hole is L5; the distance between the third flat bottom hole and the second flat bottom hole is L6; and the distance between the third flat bottom hole and the bottom of the cross-cutting slope is L7;

[0009] The detection calibration method includes the following steps:

[0010] Step 1: According to the diameter of the axle to be tested, select a calibration test block with the same diameter as the axle to be tested to produce the distance amplitude curve;

[0011] Step 2: Apply coupling agent evenly on the detection surface of the calibration test block, and place the ultrasonic shear wave detection probe with a refraction angle of X° on the detection surface of the test block;

[0012] Step 3: When the ultrasonic wave enters the calibration block from the probe, it will continue to propagate forward. During the propagation process, if the sound wave encounters the first flat-bottom hole, the second flat-bottom hole, the third flat-bottom hole and the reflective surface of the calibration block, it will be reflected;

[0013] Step 4: The reflected wave returns to the probe along the original path. After receiving the energy of the reflected wave, the probe converts it into an electrical signal, i.e. the reflected wave on the fluorescent screen.

[0014] Step 5: At this point, by observing the position and height of the reflected wave on the fluorescent screen, the buried depth and size of the flat-bottom hole and the condition of the reflective surface of the test block can be accurately determined.

[0015] As a further solution of the present invention, the cross-cutting inclined surface has the same diameter as the transition arc portion of the axle.

[0016] As a further solution of the present invention, the depths of the first flat bottom hole, the second flat bottom hole and the third flat bottom hole are all 0.2 mm.

[0017] As a further solution of the present invention, the diameters of the first flat-bottom hole, the second flat-bottom hole and the third flat-bottom hole are all 0.1 mm.

[0018] In order to solve the above problems, the present invention also proposes a method for making an ultrasonic shear wave detection calibration test block, which comprises the following steps:

[0019] Step 1: Prepare ultrasonic shear wave test calibration blocks of different diameters for testing axles of different diameters;

[0020] Step 2: The calibration test block is made of a test block blank whose material and heat treatment status are exactly the same as the axle product being tested, and whose surface status, type and size are the same or similar to the axle product being tested.

[0021] Step 3: The artificial defects on the calibration test block are made into flat-bottom holes with different positions, different burial depths and the same aperture according to the technical standards for axle products.

[0022] As a further solution of the present invention, the method for preparing the distance amplitude curve in step 1 includes:

[0023] Step 1: Place the ultrasonic shear wave detection probe on the detection surface of the test block, move the probe to find the maximum reflection echo of the first flat bottom hole on the test block and adjust it to 50% height of the full screen, and mark point 1;

[0024] Step 2: Detect the second flat bottom hole and the third flat bottom hole on the calibration test block respectively, find the maximum reflection echo of the second flat bottom hole and the third flat bottom hole and adjust them to 50% height of the full screen, and make corresponding marking points 2 and 3;

[0025] Step 3: Smoothly connect points 1, 2, and 3, and extend them to the entire detection range, thus completing the production of the ultrasonic shear wave radial detection distance amplitude curve based on the aperture of фZmm.

[0026] Compared with the prior art, the present invention has the following beneficial effects:

[0027] 1. The present invention realizes ultrasonic shear wave detection of the transition arc part of the step of the axle product of a railway locomotive and vehicle by making an ultrasonic shear wave detection calibration test block for the transition arc part of the step of the axle product of the railway locomotive and vehicle. It also has the advantages of fast detection speed and low detection cost. At the same time, the test block is exquisitely designed and compact, which is convenient for the operator to operate and is simple and practical. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for describing the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0029] Figure 1 Schematic diagram of ultrasonic radial detection of the straight part of the axle in the present invention;

[0030] Figure 2 It is a schematic diagram of ultrasonic shear wave radial detection of the transition arc part of the axle of the present invention;

[0031] Figure 3It is a schematic diagram of the ultrasonic shear wave radial calibration test block at the transition arc portion of the axle in the present invention;

[0032] Figure 4 Schematic diagram of the ultrasonic shear wave radial calibration test block at the transition arc portion of the axle in the present invention

[0033] Figure 5 A schematic diagram of the ultrasonic shear wave radial detection distance amplitude curve produced in the present invention;

[0034] Figure 6 It is a schematic diagram of ultrasonic shear wave radial detection of the transition arc part of the axle of the present invention;

[0035] Figure 7 This is a flow chart of the detection and calibration method in the present invention;

[0036] Figure 8 is a flow chart of the method for making a calibration test block in the present invention;

[0037] Fig. 9 It is a flow chart of the method for making the distance amplitude curve in the present invention. DETAILED DESCRIPTION

[0038] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0039] See also Figure 1-9 , the present invention provides a technical solution: an ultrasonic shear wave detection calibration test block for the transition arc part of the step of the axle product of a railway locomotive and vehicle, comprising a calibration test block with a length dimension of L and a diameter dimension of ф and an ultrasonic shear wave detection probe, the end of the calibration test block is provided with a cross-cutting inclined surface with an angle of X° with the axis of the calibration test block, three burial depths are vertically drilled on the long axis center line of the cross-cutting inclined surface, namely a first flat bottom hole, a second flat bottom hole and a third flat bottom hole, the first flat bottom hole, the second flat bottom hole and the third flat bottom hole are all Ymm deep, and the hole diameters are all фZmm;

[0040] The calibration sound path sizes of the first flat bottom hole, the second flat bottom hole and the third flat bottom hole are L1, L2 and L3 respectively; the distance between the first flat bottom hole and the top of the cross-cutting slope is L4; the distance between the second flat bottom hole and the first flat bottom hole is L5; the distance between the third flat bottom hole and the second flat bottom hole is L6; and the distance between the third flat bottom hole and the bottom of the cross-cutting slope is L7;

[0041] During the inspection and calibration, ultrasonic shear wave inspection calibration test blocks of different diameters are made according to the inspection requirements of the axle products to be inspected, and are used for the inspection of axles of different diameters. The artificial defects on the calibration test blocks are made into flat-bottom holes of different positions, different burial depths and the same aperture according to the technical standards of axle products. According to the diameter of the axle to be inspected, a calibration test block with the same diameter as the axle to be inspected is selected to make the distance amplitude curve. Then, the coupling agent is evenly applied on the inspection surface of the calibration test block, and the ultrasonic shear wave detection probe with a refraction angle of X° is placed on the inspection surface of the calibration test block. When the ultrasonic wave is transmitted from the ultrasonic After the acoustic shear wave detection probe enters the calibration test block, it will continue to propagate forward. During the propagation process, if the acoustic wave encounters the first flat-bottom hole, the second flat-bottom hole, the third flat-bottom hole and the reflective surface of the calibration test block, it will be reflected. The reflected wave will return to the probe along the original path. After receiving the energy of the reflected wave, the probe converts it into an electrical signal, namely the reflected wave on the fluorescent screen, including the defect reflected wave and the reflective wave of the test block reflective surface. At this time, by observing the position and height of the reflected wave on the fluorescent screen, the buried depth and size of the flat-bottom hole and the condition of the reflective surface of the test block can be accurately determined, thereby achieving the purpose of instrument calibration and product testing.

[0042] As a further solution of the present invention, the cross-cutting inclined surface has the same diameter as the transition arc portion of the axle to be detected; the ultrasonic detection propagation angle is increased to ensure that the transition arc portion of the axle can be detected.

[0043] As a further solution of the present invention, the first flat bottom hole, the second flat bottom hole and the third flat bottom hole are all 0.2 mm deep, which can detect axle scars with a depth of 0.2 mm.

[0044] As a further solution of the present invention, the first flat bottom hole, the second flat bottom hole and the third flat bottom hole have a diameter of 0.1 mm, which can detect axle scars with a diameter of 0.2 mm.

[0045] In order to solve the above problems, the present invention also proposes a method for making an ultrasonic shear wave detection calibration test block, which comprises the following steps:

[0046] Step 1: Make ultrasonic shear wave test calibration blocks of different diameters for testing axles of different diameters, so as to facilitate testing of various axle models;

[0047] Step 2: The calibration test block is made of a test block blank with the same material and heat treatment status as the axle product being tested, and the same or similar surface status, type and size as the axle product being tested, to ensure the accuracy of the value transfer during the test;

[0048] Step 3: The artificial defects on the calibration test block are made into flat-bottom holes of different positions, different burial depths and the same aperture according to the technical standards of axle products, so as to facilitate the detection of injuries of different sizes inside the axle.

[0049] As a further solution of the present invention, the method for preparing the distance amplitude curve in step 1 includes:

[0050] Step 1: Place the ultrasonic shear wave detection probe on the detection surface of the test block, move the probe to find the maximum reflection echo of the first flat bottom hole on the test block and adjust it to 50% height of the full screen, and mark point 1;

[0051] Step 2: Detect the second flat bottom hole and the third flat bottom hole on the calibration test block respectively, find the maximum reflection echo of the second flat bottom hole and the third flat bottom hole and adjust them to 50% height of the full screen, and make corresponding marking points 2 and 3;

[0052] Step 3: Smoothly connect points 1, 2, and 3, and extend them to the entire detection range, thus completing the production of the ultrasonic shear wave radial detection distance amplitude curve based on the aperture of фZmm, which is convenient for observing and calculating the specific location of the trauma.

[0053] Working principle: During the inspection and calibration, ultrasonic shear wave inspection calibration blocks of different diameters are made according to the inspection requirements of the inspected axle products for the inspection of axles of different diameters. The artificial defects on the calibration blocks are made into flat-bottom holes of different positions, different burial depths and the same aperture according to the technical standards of axle products. According to the diameter of the inspected axle, a calibration block with the same diameter as the inspected axle is selected to make the distance amplitude curve. Then, the coupling agent is evenly applied on the inspection surface of the calibration block, and the ultrasonic shear wave detection probe with a refraction angle of X° is placed on the inspection surface of the calibration block. When the ultrasonic After the ultrasonic shear wave detection probe enters the calibration test block, it will continue to propagate forward. During the propagation process, if the sound wave encounters the first flat-bottom hole, the second flat-bottom hole, the third flat-bottom hole and the reflective surface of the calibration test block, it will be reflected. The reflected wave will return to the probe along the original path. After receiving the energy of the reflected wave, the probe converts it into an electrical signal, namely the reflected wave on the fluorescent screen, including the defect reflection wave and the reflection wave of the test block reflection surface. At this time, by observing the position and height of the reflected wave on the fluorescent screen, the buried depth and size of the flat-bottom hole and the condition of the reflective surface of the test block can be accurately determined, thereby achieving the purpose of instrument calibration and product testing.

[0054] In the description of this specification, the description with reference to the terms "one embodiment", "example", "specific example", etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0055] The preferred embodiments of the present invention disclosed above are only used to help explain the present invention. The preferred embodiments do not describe all the details in detail, nor do they limit the invention to only specific implementation methods. Obviously, many modifications and changes can be made according to the content of this specification. This specification selects and specifically describes these embodiments in order to better explain the principles and practical applications of the present invention, so that those skilled in the art can understand and use the present invention well. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. A method for calibrating ultrasonic shear wave detection of transition arc parts of railway vehicle axles, comprising a calibration test block with a length dimension of L and a diameter dimension of ф and an ultrasonic shear wave detection probe, characterized in that: The end of the calibration test block is provided with a transverse inclined plane at an angle of X° to the axis of the calibration test block, and three buried depths are vertically drilled on the center line of the long axis of the transverse inclined plane, namely the first flat bottom hole, the second flat bottom hole and the third flat bottom hole, the first flat bottom hole, the second flat bottom hole and the third flat bottom hole are all 0.2 mm deep and 0.1 mm in diameter; The calibration sound path sizes of the first flat bottom hole, the second flat bottom hole and the third flat bottom hole are L1, L2 and L3 respectively; the distance between the first flat bottom hole and the top of the cross-cutting slope is L4; the distance between the second flat bottom hole and the first flat bottom hole is L5; the distance between the third flat bottom hole and the second flat bottom hole is L6; and the distance between the third flat bottom hole and the bottom of the cross-cutting slope is L7; The detection calibration method includes the following steps: Step 1: According to the diameter of the axle to be tested, a calibration test block with the same diameter as the axle to be tested is selected to prepare a distance amplitude curve; the method for preparing the distance amplitude curve includes: S1: Place the ultrasonic shear wave detection probe on the detection surface of the test block, move the probe to find the maximum reflection echo of the first flat-bottom hole on the test block and adjust it to 50% of the full screen height, and mark point 1; S2: Detect the second flat bottom hole and the third flat bottom hole on the calibration test block respectively, find the maximum reflection echo of the second flat bottom hole and the third flat bottom hole and adjust them to 50% height of the full screen, and make corresponding marking points 2 and 3; S3: Smoothly connect the marking points 1, 2, and 3 and extend them to the entire detection range, thus completing the production of the ultrasonic shear wave radial detection distance amplitude curve based on an aperture of 0.1 mm; Step 2: Apply coupling agent evenly on the detection surface of the calibration test block, and place the ultrasonic shear wave detection probe with a refraction angle of X° on the detection surface of the test block; Step 3: When the ultrasonic wave enters the calibration block from the probe, it will continue to propagate forward. During the propagation process, if the sound wave encounters the first flat-bottom hole, the second flat-bottom hole, the third flat-bottom hole and the reflective surface of the calibration block, it will be reflected; Step 4: The reflected wave returns to the probe along the original path. After receiving the energy of the reflected wave, the probe converts it into an electrical signal, i.e. the reflected wave on the fluorescent screen. Step 5: At this point, the buried depth and size of the flat-bottom hole and the condition of the reflective surface of the test block can be accurately determined by observing the position and height of the reflected wave on the fluorescent screen; The cross-cutting inclined surface has the same diameter as the transition arc portion of the axle to be detected.

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