Manufacturing method of small bar ultrasonic reference block

Abstract

The invention discloses a manufacturing method of a small bar ultrasonic reference block, the reference block comprises a body reference block and extension sections in threaded connection with two ends of the body reference block, screw rods are arranged at two ends of the body reference block, and a flat-bottomed hole and a transverse hole are formed in the body reference block; the manufacturing method comprises the steps of calculating the diameter d of the screw, processing the body reference block, processing the extension section and combining. According to the method, precious body materials of the small bar ultrasonic reference block can be reduced, few precious metal materials are used, the weight of the reference block is reduced, the overall weight is light, the manufacturing cost and the labor intensity are reduced, and the detection quality is improved. The reference block is easy to center, detection is carried out on a required machine, the length meets the detection requirement, and the reference block is detachable and easy to store.

Description

Technical Field

[0001] The invention belongs to the technical field of ultrasonic contrast test block processing, and in particular relates to a method for manufacturing a small bar ultrasonic contrast test block. Background Art

[0002] At present, the automation level of ultrasonic flaw detection of small bars is getting higher and higher. The ultrasonic comparison test block required to be used is generally required to be 1000mm~2000mm in length. The length of the manual ultrasonic flaw detection comparison test block is generally about 150mm, which cannot meet the requirements of automated flaw detection equipment and needs to be extended to 1000mm~2000mm. The traditional method is to use 1000mm~2000mm bars for direct processing and process the transverse holes on the end face of the bars. For aerospace engines, titanium alloys, high-temperature alloys and other metal materials are often used, which are expensive and bulky. For automated testing equipment, the method of centering with guide sleeves at both ends is used, and it is difficult to center with one end suspended in the air.

[0003] The Chinese invention patent with publication number CN116698992A discloses a comparative test block and design method. For special forgings with rounded structures, in actual operation, in the profiling scan, under the premise of the rounded structure, no effective echo can be obtained after the angle deflection step, so the detection range may not cover the far field area of ​​the rounded structure, resulting in missed detection. However, this test block cannot solve the problem faced by small bars in the present invention. Summary of the invention

[0004] In order to solve the above problems, the present invention aims to provide a method for making a small bar ultrasonic comparison test block.

[0005] In order to achieve the above-mentioned purpose, the present invention adopts the following technical scheme: a method for manufacturing a small bar ultrasonic contrast test block, the contrast test block includes a main body contrast test block and an extension section threadedly connected at both ends thereof, the main body contrast test block is provided with screws at both ends, and a flat bottom hole and a horizontal hole are opened inside, and the manufacturing method includes the following steps:

[0006] Step 1: Calculate the screw diameter. According to the required diameter D of the body comparison test block, use the formula d1 = D-0.3 × D × 2 to calculate the estimated diameter d1 of the connecting screws at both ends of the body comparison test block. According to the commonly used processing size of the thread, round d1 to get the screw diameter d;

[0007] Step 2: Process the body comparison test block. Use a bar with the same material and state as the inspected part to process the body comparison test block. The length of the body comparison test block is L1. The screw diameters at both ends of the body comparison test block are d calculated in step 1, and the length of the screw is L3.

[0008] Step 3: Process the extension section. The extension section is made of lightweight, corrosion-resistant, non-absorbent and rigid material, and threaded holes are opened at both ends. The length of the extension section is L2. The extension section is treated with rust and corrosion prevention.

[0009] Assembly: Install the extension section on both ends of the main body comparison test block through threaded connection to form a comparison test block, and remove burrs on the edges and corners.

[0010] Preferably, the required diameter of the body comparison test block in step 1 is rounded, and the rounded screw diameter d is smaller than the estimated screw diameter d1.

[0011] Preferably, in step 2, the main body comparison test block is provided with a first transverse hole, a second transverse hole, a first flat-bottom hole, a third flat-bottom hole and a second flat-bottom hole therebetween.

[0012] Preferably, the diameter of the threaded hole is d, the threaded hole is threadedly connected to the screw rod, and the depth of the threaded hole is greater than the length L3 of the screw rod.

[0013] Preferably, the total length L of the comparison test block is the length L1 of the main comparison test block and the length L3 of the extension sections at both ends, that is, L=L1+2*L2, and the length of L is 1000mm~2000mm, which can be detected on automated flaw detection equipment.

[0014] Compared with the prior art, the present invention has the following advantages: the method can reduce the precious body material of the small bar ultrasonic comparison test block, use less precious metal materials, reduce the weight of the comparison test block, lighten the overall weight, reduce manufacturing costs and labor intensity, and improve the detection quality. The comparison test block is easy to center and can be tested on the required machine. The length meets the detection requirements and can be disassembled for easy storage. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to more clearly illustrate the technical solutions in the specific embodiments of the present invention, the drawings required for use in the description of the embodiments will be 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 paying creative work.

[0016] Figure 1 It is a schematic diagram of the overall structure of the comparison test block in the present invention;

[0017] Figure 2 for Figure 1 A magnified image of point A;

[0018] In the figure, 1-body comparison test block; 2-extension section; 3-screw; 4-threaded hole; 5-first transverse hole; 6-second transverse hole; 7-first flat bottom hole; 8-second flat bottom hole; 9-third flat bottom hole. DETAILED DESCRIPTION

[0019] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments, but it should not be understood that the scope of the subject matter described in the present invention is limited to the following embodiments. Without departing from the above-mentioned technical ideas of the present invention, various modifications, substitutions and changes made according to the common technical knowledge and customary means in the field are included in the scope of the present invention.

[0020] Reference Figure 1 , a method for making a small bar ultrasonic comparison test block, the processing method is:

[0021] 1. Calculate the diameter d of screw 3. According to the diameter of the part to be tested, round it to the diameter D of the comparison test block to be processed. According to the formula d1=D-0.3×D×2, calculate d1. According to the commonly used processing size of the thread, round d1 to the diameter d of screw 3. d is smaller than d1.

[0022] 2. Processing the body comparison test block 1, using the rod material with the same material and state as the inspected part to process the body comparison test block 1, the body comparison test block 1 is distributed with the first transverse hole 5, the second transverse hole 6, the first flat-bottom hole 7, the third flat-bottom hole 9 and the second flat-bottom hole 8 between the two, the spacing between each transverse hole and the flat-bottom hole meets the requirements of relevant standards, and the hole diameter, hole depth and position of each transverse hole and the flat-bottom hole are tested and sealed after passing the test.

[0023] The total length of both ends of the main body comparison test block 1 is L1, and a screw rod 3 is processed at each end of the main body comparison test block 1. The diameter of the screw rod 3 is d, and the length of the screw rod 3 is L3.

[0024] 3. Process the extension section 2. The extension section 2 is made of lightweight, corrosion-resistant, non-absorbent and rigid material. The outer diameter of the extension section 2 is D, and the length of the extension section 2 is L2. The total length of both ends of the main body comparison test block 1 is L1 + 2 times the length of the extension section 2. L2 is the total length of the comparison test block L. The length of L is determined according to needs. A threaded hole 4 is processed at one end of the extension section 2. The diameter of the threaded hole 4 is d, and the depth of the threaded hole 4 is greater than the length L3 of the screw 3.

[0025] 4. Assemble, screw the processed extension section 2 onto the two ends of the main body comparison test block 1 to form a comparison test block, and remove the burrs on the edges and corners.

[0026] Example 1, a method for making a small bar ultrasonic comparison test block, the processing method is:

[0027] 1. Calculate the diameter d of the screw 3. According to the diameter of the part to be tested, which is 19 mm, round it up to the diameter D of the comparison test block to be processed, which is 19 mm. According to the formula d1=D-0.2×D×2, d1 is calculated to be 11.4 mm. According to the commonly used processing dimensions of the thread, d1 is rounded up, and the screw diameter d is 10 mm, which is smaller than d1.

[0028] 2. Processing the main body comparison test block 1, using the high-temperature alloy rod with the same material and state as the inspected part to process the main body comparison test block 1, the main body comparison test block 1 is distributed with a first transverse hole 5, a second transverse hole 6, a first flat-bottom hole 7, a third flat-bottom hole 9 and a second flat-bottom hole 8 therebetween, the spacing between each transverse hole and flat-bottom hole meets the requirements of relevant standards, the aperture, depth and position of each transverse hole and flat-bottom hole are sealed after being tested and qualified, the total length of both ends of the main body comparison test block 1 is L1, and L1 is designed to be 200mm, a screw 3 is processed at each end of the main body comparison test block 1, the diameter of the screw 3 is d, d is 10mm, the length of the screw 3 is L3, and L3 is designed to be 25mm.

[0029] 3. Process the extension section 2. The extension section 2 is made of lightweight, corrosion-resistant, non-absorbent and rigid aluminum alloy material. The outer diameter of the extension section 2 is D, D is 19 mm, the length of the extension section 2 is L2, L2 is 900 mm, the total length of both ends of the main body comparison test block 1 is L1 + 2 times the length of the extension section 2 L2 is the total length L of the comparison test block, and the length of L is determined to be 2000 mm as needed. A threaded hole 4 is processed at one end of the processed extension section 2, the diameter d of the threaded hole 4 is 10 mm, and the depth of the threaded hole 4 is greater than the length of the screw 3, which is 25 mm. After processing, the processed extension section 2 is anodized.

[0030] 4. Assemble, screw the processed extension section 2 onto the two ends of the main body comparison test block 1 to form a comparison test block, and remove the burrs on the edges and corners.

[0031] The obtained comparison test block is placed in an automated flaw detection device for testing, and meets the testing requirements. The comparison test block manufacturing method can reduce the use of precious body materials of small bar ultrasonic comparison test blocks, reduce the weight of the comparison test blocks, reduce manufacturing costs and labor intensity, and improve the testing quality.

[0032] The above is a detailed introduction to the method for making a small bar ultrasonic comparison test block provided by the present invention. This article uses specific examples to illustrate the structure and working principle of the present invention. The description of the above embodiments is only used to help understand the method and core idea of ​​the present invention. It should be pointed out that for ordinary technicians in this technical field, without departing from the principle of the present invention, the present invention can also be improved and modified in several ways, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. A method for making a small bar ultrasonic comparison test block, characterized in that: The comparison test block comprises a main body comparison test block (1) and an extension section (2) threadedly connected at both ends thereof. The main body comparison test block (1) is provided with screw rods (3) at both ends thereof and has a flat bottom hole and a transverse hole opened therein. The manufacturing method comprises the following steps: Step 1: Calculate the diameter of the screw (3). According to the required diameter D of the main body comparison test block (1), the estimated diameter d1 of the screw (3) connected at both ends of the main body comparison test block (1) is calculated using the formula d1=D-0.3×D×2. According to the commonly used processing size of the thread, d1 is rounded to obtain the diameter d of the screw (3); Step 2: Processing a body comparison test block (1), using a rod with the same material and state as the inspected part to process the body comparison test block (1), the length of the body comparison test block (1) is L1, the diameter of the screw (3) at both ends of the body comparison test block (1) is d calculated in step 1, and the length of the screw (3) is L3; Step 3: Processing the extension section (2), the extension section (2) is made of a lightweight, corrosion-resistant, non-absorbent and rigid material, and threaded holes (4) are provided at both ends of the extension section (2), the length of the extension section (2) is L2, and the extension section (2) is treated with rust and corrosion prevention; Step 4: Assemble and install the extension section (2) on both ends of the main body comparison test block (1) through threaded connection to form a comparison test block, and remove burrs on the edges and corners.

2. The method for making a small bar ultrasonic comparison test block according to claim 1, characterized in that: In the step 1, rounding is required, and the rounded diameter d of the screw (3) is smaller than the estimated diameter d1 of the screw (3).

3. The method for making a small bar ultrasonic comparison test block according to claim 1, characterized in that: In the step 2, the main body comparison test block (1) is provided with a first transverse hole (5), a second transverse hole (6), a first flat bottom hole (7), a third flat bottom hole (9) and a second flat bottom hole (8) therebetween.

4. The method for making a small bar ultrasonic comparison test block according to claim 1, characterized in that: The diameter of the threaded hole (4) is d, the threaded hole (4) is threadedly connected to the screw rod (3), and the depth of the threaded hole (4) is greater than the length L3 of the screw rod (3).

5. The method for making a small bar ultrasonic comparison test block according to claim 1, characterized in that: The total length L of the comparison test block is the length L1 of the main comparison test block (1) and the length L3 of the extension sections (2) at both ends, that is, L=L1+2*L2, and the length of L is 1000mm to 2000mm, which can be tested on an automated flaw detection device.

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