A composite material ultrasonic contrast block artificial defect manufacturing tool and method

Abstract

The application discloses a kind of composite material ultrasonic contrast test block artificial defect manufacturing tool and method, belong to composite material ultrasonic detection technical field, manufacturing tool includes tail cross and rotary connection top plate portion and bottom plate portion, top plate portion is connected with magnetic die by magnetic attraction, bottom plate portion is equipped with the matching block backing plate of magnetic die, artificial defect is manufactured in cooperation, bottom plate portion is equipped with compartment collection groove, and manufacturing and classification collection are completed simultaneously.Use, first utilize polytetrafluoroethylene film and single-sided adhesive aluminum foil to make overall blank, and then use manufacturing tool to complete artificial defect manufacturing and classification collection.The application solves the problems of traditional artificial defect manufacturing mode, such as large operation difficulty, low production efficiency, poor artificial defect quality, difficult detection of manufactured artificial defect, low pass rate of contrast test block, etc., and avoids the problem of undetectable artificial defect caused by poor aluminum foil wrapping quality, and can be widely applied in the field of composite material ultrasonic detection technology.

Description

Technical Field

[0001] This invention belongs to the field of ultrasonic testing technology for composite materials, and relates to a tool and method for creating artificial defects in ultrasonic comparison test blocks of composite materials. Background Technology

[0002] Ultrasonic testing is a non-destructive testing technique that uses ultrasonic waves to inspect artificial defects inside manufactured parts. Composite material parts are typically inspected for artificial defects such as delamination and porosity using ultrasonic testing. This process often requires a comparison test block made of the same material and manufactured as the part to calibrate the testing sensitivity. A composite material ultrasonic comparison test block generally consists of composite material layups identical to the part and artificially embedded defects. These artificial defects simulate inclusions or delaminations of different locations and sizes within the part. The ultrasonic pulses emitted by the probe are reflected at the artificial defects, and the probe receives the signal and converts it into electrical pulses displayed on a screen to identify the artificial defect.

[0003] Due to the unique and complex molding process of composite materials, ultrasonic comparison test blocks require a large number of artificial defects of different sizes, shapes, and thicknesses to be placed at different locations on the composite materials. For large and complex parts, the number of artificial defects can reach hundreds, necessitating the preparation of a large number of artificial defects in advance. The traditional method for preparing artificial defects involves stacking two layers of PTFE film coated with release agent, placing a punch with a punch size and shape matching the requirements of the artificial defect on top of the PTFE film, and applying impact force from behind the punch to obtain a double-layer PTFE film that meets the requirements. Then, aluminum foil is used to manually wrap the double-layer PTFE film within the film. In this traditional method, the process of punching out the PTFE film with a punch poses certain safety hazards, as it can easily injure the operator's hands. Furthermore, the subsequent manual wrapping of the PTFE film with aluminum foil is difficult to operate and has low production efficiency. Especially for small-sized artificial defects, such as Φ3mm, the wrapping efficiency is often extremely low, the wrapping effect is poor, and the artificial defects are difficult to detect, resulting in a low pass rate for the comparison test blocks. Summary of the Invention

[0004] The purpose of this invention is to provide a tool and method for manufacturing artificial defects in ultrasonic comparison test blocks of composite materials, so as to solve the problems of cumbersome operation, low production efficiency and low detection rate of traditional manufacturing methods.

[0005] The present invention adopts the following technical solution:

[0006] A tool for creating artificial defects in a composite ultrasonic contrast test block, comprising a top plate and a bottom plate, both of which are elongated and cross at their ends to form a clamping handle 19, making the tool as a whole X-shaped. The two plates are rotatably connected at their intersection by a bolt shaft 20, and a spring 21 is provided between their ends to provide a rebound force.

[0007] The top plate includes a multi-slot top plate 5, a die opening 6, slots 7, and a rubber clamping strip 8. The multi-slot top plate 5 is the main body of the top plate, and its lower surface has multiple slots 7 of the same size, which are used in combination with the die opening 6. The non-working end of the die opening 6 is of a fixed size and matches the slot 7. The two are combined by magnetic attraction, which facilitates the replacement of the die opening 6, is efficient and quick, and eliminates the traditional bolt disassembly and replacement process. The working end of the die opening 6 is customized with different sizes according to the actual needs of human defects. A boss is provided in the middle of the lower surface of the multi-slot top plate 5 along the width direction. A clamping strip 8 is attached to the top of the boss. The clamping strip 8 is made of silicone rubber and is used to clamp the whole blank 4.

[0008] The base plate includes a hollowed-out clamping plate 9, a clearance hole 10, a collection device 11, a segmented pad 12, a segmented collection groove 13, a cover plate 14, a support platform 15, a clearance groove 16, a defect collection port 17, and rivets 18. The collecting device 11 is the main body of the base plate. Its head is a hollow box with an open bottom. A slide rail is provided at the bottom opening to slide the cover plate 14. The upper surface of the collecting device 11 has multiple openings, the positions of which correspond one-to-one with the slots 7. Each opening has a slide rail to slide the segmented pad plate 12. The interior of the collecting device 11 is divided into multiple segmented collecting slots 13, each corresponding to an opening on the upper surface. A clearance groove 16 and a support platform 15 are provided in the middle of the upper surface of the collecting device 11. The two are arranged side by side along the width direction of the collecting device 11, with the support platform 15 near the tail. The clearance groove 16 corresponds to the protrusion on the lower surface of the multi-slot top plate 5, reserving space for the rubber clamping strip 8 to press the whole blank 4. Several segmented pad plates 12 are provided and can be detached by a slide rail. The segmented pad 12 is installed at the opening on the upper surface of the collecting device 11. It is used in a one-to-one correspondence with the die 6. The segmented pad 12 has a defect collection port 17. The shape of the defect collection port 17 matches the shape of the working end of the die 6 to create artificial defects. The artificial defects are then placed into the corresponding compartmentalized collection groove 13 below to achieve compartmentalized collection of artificial defects of different sizes, avoiding mixed placement and difficulty in identification. The hollow clamping plate 9 covers the head of the collecting device 11 and is fixed to the support platform 15 by rivets 18. It is used to clamp the whole blank 4 between it and the collecting device 11. The hollow clamping plate 9 is provided with a number of clearance holes 10. The position of the holes is set according to the opening position on the upper surface of the collecting device 11, and the size is larger than the working end of the die 6. It is used to make room for the die 6 to create artificial defects.

[0009] A method for manufacturing artificial defects in a composite material ultrasonic comparison specimen, based on the aforementioned artificial defect manufacturing tool, includes the following steps:

[0010] Step 1: Apply release agent to both sides of two polytetrafluoroethylene films 1 and let them dry. Adhere them together with a layer of double-sided adhesive tape 2. Adhere single-sided adhesive aluminum foil 3 to the outer layer of each film to completely cover the polytetrafluoroethylene film 1 and obtain the whole blank 4.

[0011] Step 2: Select the mold opening 6 and the corresponding size of the segmented pad 12 as needed, install the mold opening 6 in the slot 7 respectively, and install the segmented pad 12 at the opening on the upper surface of the collecting device 11.

[0012] Step 3: After installation, place the whole blank 4 between the hollow clamping plate 9 and the collection device 11, apply force to the clamping handle 19, so that the pressing strip 8 presses the whole blank 4 through the hollow clamping plate 9. Continue to apply force, and the mold opening 6 passes through the hollow clamping plate 9 and cooperates with the defect collection port 17 on the segmented pad 12 to complete the manufacturing of artificial defects of a specific size. The completed artificial defects fall into the corresponding segmented collection groove 13.

[0013] Step 4: Release the clamping handle 19, move the entire blank 4, and reapply force until all the required artificial defects are manufactured.

[0014] Step 5: Turn the artificial defect manufacturing tool over, pull out the cover plate 14, and take out artificial defects of different sizes in sequence, classify and store them for later use.

[0015] The beneficial effects of this invention are as follows: The special tool for manufacturing artificial defects designed in this invention features a replaceable magnetic die opening, eliminating the need for traditional bolt disassembly and die replacement. It adopts an integrated manufacturing and storage design, with a compartmentalized collection slot on the tool's base plate, allowing manufacturing and sorting to be completed simultaneously for greater efficiency and speed. The hollowed-out clamping plate design ensures the blank is tightly compressed without affecting the die opening's operation, improving the edge quality of manufactured artificial defects. This invention solves the problems of high operational difficulty, low production efficiency, poor quality of artificial defects, difficulty in detecting manufactured artificial defects, and low pass rate of comparative test blocks in traditional artificial defect manufacturing methods. The integral blank design eliminates the manual aluminum foil wrapping process, significantly reducing operational difficulty and avoiding the problem of undetectable artificial defects due to poor aluminum foil wrapping quality. This invention breaks through the technical barriers of traditional ultrasonic comparative test block artificial defect manufacturing, achieving efficient and high-pass-rate manufacturing of artificial defects, and can be widely applied in the field of ultrasonic testing technology for composite materials. Attached Figure Description

[0016] Figure 1Here are schematic diagrams of the entire billet, where (a) is a schematic diagram of the layers of the entire billet, and (b) is a schematic diagram of the entire billet as a whole;

[0017] Figure 2 This is a schematic diagram of the top slab.

[0018] Figure 3 A schematic diagram of a tool for creating artificial defects;

[0019] Figure 4 The diagram shows the base plate, where (a) is a partial view of the base plate and (b) is a schematic diagram of the segmented pad plate.

[0020] Figure 5 This is a schematic diagram of the outer side of the base plate.

[0021] Figure 6 A schematic diagram illustrating the use of tools for creating artificial defects;

[0022] Among them, 1 is polytetrafluoroethylene film; 2 is double-sided adhesive; 3 is single-sided adhesive aluminum foil; 4 is integral blank; 5 is multi-slot top plate; 6 is die opening; 7 is slot; 8 is clamping strip; 9 is hollow clamping plate; 10 is clearance hole; 11 is collection device; 12 is segmented pad plate; 13 is segmented collection trough; 14 is cover plate; 15 is support platform; 16 is clearance groove; 17 is defect collection port; 18 is rivet; 19 is clamping handle; 20 is bolt shaft; 21 is spring. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this invention clearer, the specific embodiments of this invention will be described in detail below.

[0024] This embodiment takes the fabrication of an ultrasonic contrast test block that requires the embedding of artificial defects as an example. A total of 30 circular artificial defects with diameters of Φ3mm, Φ5mm and Φ8mm and 30 square artificial defects of 5mm×5mm are required.

[0025] This embodiment provides a tool for creating artificial defects in ultrasonic comparative test blocks of composite materials. The tool includes a top plate and a bottom plate, both of which are elongated and cross at their ends to form a clamping handle 19, making the tool as a whole X-shaped. The two plates are rotatably connected at their intersection by a bolt shaft 20, and a spring 21 is provided between their ends to provide a rebound force.

[0026] like Figure 2 and Figure 3As shown, the top plate includes a multi-slot top plate 5, a die opening 6, slots 7, and a rubber clamping strip 8. The multi-slot top plate 5 is the main body of the top plate, and its lower surface has four slots 7 of the same size, each Φ3.1mm, which are used in combination with the die opening 6. The non-working end of the die opening 6 is a fixed size of Φ3mm, which matches the slot 7. The two are combined by magnetic attraction, which facilitates the replacement of the die opening 6, is efficient and quick, and eliminates the traditional bolt disassembly and replacement process. The working end of the die opening 6 is customized in different sizes according to the actual needs of the defect. In this embodiment, four sizes of die opening 6 are required: Φ3mm, Φ5mm, Φ8mm, and 5mm×5mm. A boss is provided in the middle of the lower surface of the multi-slot top plate 5 along the width direction. A clamping strip 8 is attached to the top of the boss. The clamping strip 8 is made of silicone rubber and is used to clamp the entire blank 4.

[0027] like Figure 3 and Figure 4 As shown, the base plate includes a perforated clamping plate 9, a clearance hole 10, a collection device 11, a segmented pad 12, a segmented collection groove 13, a cover plate 14, a support platform 15, a clearance groove 16, a defect collection port 17, and rivets 18. The collection device 11 is the main body of the base plate, with its head being a hollow box with an open bottom. A slide rail is provided at the open bottom to allow the cover plate 14 to be slidably installed (e.g., ...). Figure 5The collecting device 11 has four openings on its upper surface, each corresponding to a slot 7. Each opening has a slide rail for slidingly mounting the segmented pad 12. The inside of the collecting device 11 is divided into four segmented collecting slots 13, each corresponding to an opening on the upper surface. A clearance groove 16 and a support platform 15 are located in the middle of the upper surface of the collecting device 11, arranged side-by-side along the width of the collecting device 11. The support platform 15 is positioned closer to the tail end. The clearance groove 16 corresponds to a protrusion on the lower surface of the multi-slot top plate 5, providing space for the rubber clamping strip 8 to press the entire blank 4. Several segmented pads 12 are provided and detachably mounted on the openings on the upper surface of the collecting device 11 via slide rails. Each segmented pad 12 corresponds to a mold opening 6. A defect collection port 17 is provided on each segmented pad 12 for defect collection. The shape of the collection port 17 matches the shape of the working end of the matching mold 6 to create artificial defects. In this embodiment, four segmented pads 12 are prepared, with defect collection ports 17 of Φ3.1mm, Φ5.1mm, Φ8.1mm and 5.1mm×5.1mm respectively. The manufactured artificial defects fall into the corresponding segmented collection grooves 13 below to achieve segmented collection of artificial defects of different sizes, avoiding mixed placement and difficulty in identification. The hollow clamping plate 9 covers the head of the collection device 11 and is fixed to the support platform 15 by rivets 18. It is used to clamp the whole blank 4 between it and the collection device 11. The hollow clamping plate 9 is provided with several clearance holes 10. The position is set according to the opening position on the upper surface of the collection device 11 and the size is larger than the working end of the mold 6 to make room for the mold 6 to make artificial defects.

[0028] Another aspect of this embodiment provides a method for manufacturing artificial defects in a composite material ultrasonic comparison specimen, based on the aforementioned artificial defect manufacturing tool. The method for manufacturing artificial defects includes the following steps:

[0029] Step 1: Apply release agent to both sides of two 300mm×200mm polytetrafluoroethylene (PTFE) films 1 and let them dry. Bond them together with a layer of 300mm×200mm double-sided adhesive tape 2. Then, attach 300mm×200mm single-sided adhesive aluminum foil 3 to the outer layers of each film, completely covering the PTFE films 1 to obtain the overall blank 4. Figure 1 .

[0030] Step 2: Select the mold opening 6 and the corresponding size of the segmented pad 12 as needed, install the mold opening 6 in the slot 7 respectively, and install the segmented pad 12 at the opening on the upper surface of the collecting device 11.

[0031] Step 3: After installation, place the whole blank 4 between the hollow clamping plate 9 and the collection device 11, apply force to the clamping handle 19, so that the pressing strip 8 presses the whole blank 4 through the hollow clamping plate 9. Continue to apply force, and the mold opening 6 passes through the hollow clamping plate 9 and cooperates with the defect collection port 17 on the segmented pad 12 to complete the manufacturing of artificial defects of a specific size. The completed artificial defects fall into the corresponding segmented collection groove 13.

[0032] Step 4: Release the clamping handle 19, move the entire blank 4, and reapply force until all required artificial defects are manufactured, such as... Figure 6 .

[0033] Step 5: Turn the artificial defect manufacturing tool over, pull out the cover plate 14, and take out artificial defects of different sizes in sequence, classify and store them for later use.

[0034] In summary, the above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A tool for manufacturing artificial defects in ultrasonic comparative test blocks of composite materials, characterized in that, The artificial defect manufacturing tool includes a top plate and a bottom plate, both of which are long and cross at the tail and rotate to form a clamping handle (19), making the artificial defect manufacturing tool as a whole X-shaped. The top plate includes a multi-slot top plate (5), a mold opening (6), and slots (7); the multi-slot top plate (5) is the main body of the top plate, and its head has multiple slots (7) on its lower surface for connecting the mold opening (6); the non-working end of the mold opening (6) is connected to the slot (7), and the size of its working end is determined according to the required artificial defects. The base plate includes a hollow clamping plate (9), a clearance hole (10), a collection device (11), a segmented pad (12), a cover plate (14), a support platform (15), and a defect collection port (17). The collection device (11) is the main body of the base plate. Its head is a hollow box with an open bottom. A cover plate (14) is provided at the open bottom. Multiple openings are provided on the upper surface of the collection device (11), and the opening positions correspond one-to-one with the slots (7). A support platform (15) is provided in the middle of the upper surface of the collection device (11) along its width direction. Several segmented pads (12) are provided and installed at the openings on the upper surface of the collection device (11). (12) is used in a one-to-one correspondence with the mold opening (6). The segmented pad (12) has a defect collection port (17). The shape of the defect collection port (17) matches the shape of the working end of the matching mold opening (6) to create artificial defects. The hollow clamping plate (9) covers the head of the collection device (11) and is fixed on the support platform (15) to clamp the whole blank (4) between it and the collection device (11). The hollow clamping plate (9) is provided with several clearance holes (10). The position is set according to the opening position on the upper surface of the collection device (11), and the size is larger than the working end of the mold opening (6) to make room for the mold opening (6) to create artificial defects.

2. The tool for manufacturing artificial defects in a composite material ultrasonic comparison test block according to claim 1, characterized in that, A spring (21) is provided between the tail of the top plate portion and the bottom plate portion to provide a restoring force.

3. The tool for manufacturing artificial defects in a composite material ultrasonic comparison test block according to claim 1, characterized in that, The mold opening (6) and the card slot (7) are connected by magnetic attraction.

4. The tool for manufacturing artificial defects in a composite material ultrasonic comparison test block according to claim 1, characterized in that, The multi-slot top plate (5) has a boss in the middle of the lower surface along the width direction for pressing the whole blank (4). The upper surface of the collecting device (11) is provided with a relief groove (16) corresponding to the boss position to reserve space for the boss to press the whole blank (4).

5. The tool for manufacturing artificial defects in a composite material ultrasonic comparison test block according to claim 4, characterized in that, A clamping strip (8) is attached to the top of the boss on the lower surface of the multi-slot top plate (5). The clamping strip (8) is made of silicone rubber.

6. The tool for manufacturing artificial defects in a composite material ultrasonic comparison test block according to claim 1, characterized in that, The collection device (11) has a slide at the bottom opening to slide the cover plate (14).

7. The tool for manufacturing artificial defects in a composite material ultrasonic comparison test block according to claim 1, characterized in that, Each opening of the collection device (11) is provided with a slide for sliding installation of the segmented pad (12).

8. The tool for manufacturing artificial defects in a composite material ultrasonic comparison test block according to claim 1, characterized in that, The collection device (11) is divided into multiple compartmentalized collection slots (13), the positions of which correspond one-to-one with the openings on the upper surface of the collection device (11) to achieve compartmentalized collection of artificial defects of different sizes.

9. A method for manufacturing artificial defects in a composite material ultrasonic comparison specimen, implemented using the artificial defect manufacturing tool described in any one of claims 1-8, characterized in that, The method for creating artificial defects includes the following steps: Step 1, make the whole blank (4); Step 2: Select the mold opening (6) and the corresponding size of the segmented pad (12) as needed. Install the mold opening (6) in the slot (7) respectively, and install the segmented pad (12) at the opening on the upper surface of the collecting device (11). Step 3: After installation, place the whole blank (4) between the hollow clamping plate (9) and the collection device (11), apply force to the clamping handle (19), and the mold opening (6) passes through the hollow clamping plate (9) and matches with the defect collection port (17) on the segmented pad plate (12) to complete the artificial defect manufacturing. Step 4: Release the clamping handle (19), move the entire blank (4), and reapply force until all the required artificial defects are manufactured; Step 5: Turn the artificial defect manufacturing tool over, pull out the cover plate (14), and take out the artificial defect for later use.

10. The method for manufacturing artificial defects in a composite material ultrasonic comparison specimen according to claim 9, characterized in that, In step 1, the overall blank (4) is made by applying a release agent to both sides of two polytetrafluoroethylene films (1) and drying them. The two films are then bonded together with a layer of double-sided adhesive (2). Single-sided adhesive aluminum foil (3) is then bonded to the outer layers of the two films to completely cover the polytetrafluoroethylene films (1).

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