A method for manufacturing a small bar ultrasonic contrast test block

Abstract

The application discloses a kind of production methods of small bar ultrasonic comparison test block, comparison test block includes body comparison test block and the extension section of screw thread connection in its two ends, body comparison test block two ends are provided with screw rod, inside is opened with flat-bottom hole and transverse hole, production method includes calculating screw rod diameter d-Processing body comparison test block-Processing extension section-Combination.This method can reduce small bar ultrasonic comparison test block precious body material, use less precious metal material, reduce comparison test block weight, overall weight is light, reduce manufacturing cost and labor intensity, improve detection quality.And comparison test block is easy to center, on the machine required to detect, and length meets the detection requirement, can be disassembled and easily stored.

Description

Technical Field

[0001] This invention belongs to the field of ultrasonic comparison test block processing technology, specifically relating to a method for manufacturing a small rod ultrasonic comparison test block. Background Technology

[0002] Currently, the automation level of ultrasonic testing of small bars is becoming increasingly higher. The ultrasonic comparison test blocks used generally need to be 1000mm to 2000mm in length. The length of manual ultrasonic testing comparison test blocks is generally around 150mm, which cannot meet the requirements of automated testing equipment. It is necessary to extend it to 1000mm to 2000mm. The traditional method is to directly process 1000mm to 2000mm bars and machine the transverse holes on the end face of the bar. 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 difficult to center with one end suspended.

[0003] Chinese invention patent CN116698992A discloses a comparative test block and its design method. However, for special forgings with rounded structures, in actual contour scanning operations, under the premise of a rounded structure, effective echoes cannot be obtained after angle deflection and stepping. Therefore, the detection range may not cover the far-field region of the rounded structure, leading to missed detections. However, this test block cannot solve the problem faced by small bars in this invention. Summary of the Invention

[0004] To address the aforementioned problems, this invention aims to provide a method for fabricating a small rod-shaped ultrasonic comparison test block.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a method for manufacturing a small rod ultrasonic comparison test block, the comparison test block comprising a main body comparison test block and extension sections threaded to its two ends, the main body comparison test block having screws at both ends, and having flat-bottomed holes and transverse holes inside, the manufacturing method comprising the following steps.

[0006] Step 1: Calculate the screw diameter. Based on 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 screws connecting both ends of the body comparison test block. Round d1 according to the commonly used thread machining dimensions to obtain the screw diameter d.

[0007] Step 2: Machining the body comparison test block. The body comparison test block is machined using a bar with the same material and condition as the part under inspection. The length of the body comparison test block is L1, the diameter of the screws at both ends of the body comparison test block is d calculated in Step 1, and the length of the screws is L3.

[0008] Step 3: Process the extension section. The extension section is made of a 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 prevention and corrosion prevention.

[0009] Assembly: The extension section is installed at both ends of the main body comparison test block by threaded connection to form a comparison test block, and the edges and burrs are removed.

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

[0011] Preferably, in step 2, the body comparison test block has a first horizontal hole, a second horizontal hole, a first flat-bottomed hole, a third flat-bottomed hole, and a second flat-bottomed hole between the two.

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

[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. The length of L is 1000mm to 2000mm, which can be detected on automated flaw detection equipment.

[0014] Compared with existing technologies, this invention has the following advantages: This method can reduce the amount of expensive materials used in the ultrasonic contrast test block of small rods, using less precious metal material, reducing the weight of the contrast test block, making the overall weight lighter, reducing manufacturing costs and labor intensity, and improving detection quality. Furthermore, the contrast test block is easy to center, can be tested on the required machine, and its length meets the detection requirements; it is also detachable and easy to store. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the specific embodiments of the present invention, the drawings used 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 those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the overall structure of the comparative test block in this invention;

[0017] Figure 2 for Figure 1 Enlarged view 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 Implementation

[0019] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. However, it should not be construed that the scope of the subject matter of the present invention is limited to the following embodiments. All modifications, substitutions and alterations made based on ordinary technical knowledge and common practices in the art without departing from the above-described technical concept of the present invention are included within the scope of the present invention.

[0020] Reference Figure 1 A method for preparing a small rod-shaped ultrasonic comparative test block, the processing method being:

[0021] 1. Calculate the diameter d of screw 3. Based on the diameter of the part to be tested, round it to the nearest integer to get the diameter D of the comparison test block to be machined. Calculate d1 according to the formula d1 = D - 0.3 × D × 2. Round d1 according to the commonly used machining dimensions of threads to get the diameter d of screw 3. d is less than d1.

[0022] 2. Machining the body comparison test block 1: The body comparison test block 1 is machined using a bar stock of the same material and condition as the part under inspection. The body comparison test block 1 has 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 located between the two. The spacing between each transverse hole and flat-bottom hole meets the relevant standard requirements. After the diameter, depth, and position of each transverse hole and flat-bottom hole are inspected and approved, the hole openings are sealed.

[0023] The total length of the two ends of the comparison test block 1 is L1. A screw 3 is machined at each end of the comparison test block 1. The diameter of the screw 3 is d and the length of the screw 3 is L3.

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

[0025] 4. Assembly: Screw the processing extension section 2 onto both ends of the main body comparison test block 1 to form a comparison test block, and remove the burrs from the edges and corners.

[0026] Example 1: A method for fabricating a small rod ultrasonic comparison test block, the processing method of which is as follows:

[0027] 1. Calculate the diameter d of screw 3. Based on the diameter of the part to be tested being 19mm, round it to the nearest whole number. The diameter D of the comparison test block to be machined is 19mm. According to the formula d1=D-0.2×D×2, d1 is calculated to be 11.4mm. According to the commonly used machining dimensions for threads, d1 is rounded to the nearest whole number. The screw diameter d is 10mm. d is less than d1.

[0028] 2. Machining the body comparison test block 1: The body comparison test block 1 is machined using a high-temperature alloy bar with the same material and condition as the part under test. The body comparison test block 1 has a first horizontal hole 5, a second horizontal hole 6, a first flat bottom hole 7, a third flat bottom hole 9, and a second flat bottom hole 8 between the two. The spacing between each horizontal hole and flat bottom hole meets the relevant standard requirements. After the diameter, depth, and position of each horizontal hole and flat bottom hole are inspected and qualified, the hole openings are sealed. The total length of the two ends of the body comparison test block 1 is L1, and L1 is designed to be 200mm. A screw 3 is machined at each end of the body comparison test block 1. The diameter of the screw 3 is d, which is 10mm, and the length of the screw 3 is L3, which is designed to be 25mm.

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

[0030] 4. Assembly: Screw the processing extension section 2 onto both ends of the main body comparison test block 1 to form a comparison test block, and remove the burrs from the edges and corners.

[0031] The obtained comparison test blocks were placed in automated flaw detection equipment for testing and met the testing requirements. This method of manufacturing comparison test blocks can reduce the use of expensive materials for the small rod ultrasonic comparison test blocks, reduce the weight of the comparison test blocks, lower manufacturing costs and labor intensity, and improve testing quality.

[0032] The above provides a detailed description of the method for fabricating a small rod ultrasonic comparison test block provided by the present invention. Specific examples have been used to illustrate the structure and working principle of the invention. The descriptions of the embodiments above are merely for the purpose of helping to understand the method and core ideas of the present invention. It should be noted that those skilled in the art can make various improvements and modifications to the present invention without departing from its principles, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. A method for preparing a small rod ultrasonic comparison test block, characterized in that: The comparison test block includes a main body comparison test block (1) and an extension section (2) threaded to both ends thereon. The main body comparison test block (1) is provided with screws (3) at both ends and has a flat bottom hole and a transverse hole inside. The manufacturing method includes the following steps: Step 1: Calculate the diameter of the screw (3). Based on the required diameter D of the body comparison test block (1), use the formula d1=D-0.3×D×2 to calculate the estimated diameter d1 of the screw (3) connecting both ends of the body comparison test block (1). Round d1 according to the commonly used thread processing dimensions to obtain the diameter d of the screw (3). Step 2: Process the body comparison test block (1). The body comparison test block (1) is processed using a bar with the same material and state as the part under inspection. The length of the body comparison test block (1) is L1. The diameter of the screws (3) at both ends of the body comparison test block (1) is d calculated in Step 1. The length of the screws (3) is L3. The 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) between the two. Step 3: Process 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 opened at both ends. The length of the extension section (2) is L2. The extension section (2) is treated for rust prevention and corrosion prevention. Step 4: Assembly: Install the extension section (2) at both ends of the main body comparison test block (1) by threaded connection to form a comparison test block, and remove the burrs from the edges and corners; The total length L of the comparison test block is the length L1 of the main comparison test block (1) and the length L2 of the extension sections (2) at both ends, that is, L=L1+2*L2. The length of L is 1000mm~2000mm, which can be detected on automated flaw detection equipment. The material of the extension section (2) is different from that of the main body comparison test block (1), and the material cost of the extension section (2) is lower than that of the main body comparison test block (1).

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

3. The method for preparing a small rod 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 (3), and the depth of the threaded hole (4) is greater than the length L3 of the screw (3).

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