Part inner fillet ultrasonic detection device and part inner fillet ultrasonic detection method

Abstract

The invention relates to the field of nondestructive detection of parts, discloses an ultrasonic detection device and method for an inner fillet of a part, and solves the problems that the existing inner fillet detection is low in precision, large in man-made interference and difficult in full-coverage scanning. Comprising a supporting part, an angle-adjustable ultrasonic detection mechanism and an angle indicating mechanism, the supporting part is provided with an outer contour tangent to the contour of the cross section of the inner fillet of the to-be-detected part and a first side wall perpendicular to the cross section, and the side wall is provided with a first arc groove with the circle center coinciding with the circle center of the inner fillet. The angle-adjustable ultrasonic detection mechanism is arranged on the side face of the first side wall and comprises a wedge block, an ultrasonic probe, a sliding sleeve shell and a radial pressing mechanism which are sequentially connected from inside to outside in the radial direction. The ultrasonic probe is acoustically coupled with a to-be-detected surface through the wedge block, and the radial pressing mechanism drives the probe to apply radial pressure; the sliding sleeve shell moves along the arc groove and is fixed to achieve angle adjustment. The angle indicating mechanism indicates the angle position of the detection mechanism.

Description

Technical Field

[0001] This invention relates to the field of nondestructive testing technology for parts, specifically to an ultrasonic testing device for the inner fillet radius of a part and an ultrasonic testing method for the inner fillet radius of a part. Background Technology

[0002] With the increasingly widespread application of metal structures in the petrochemical, natural gas extraction, and storage and transportation fields, metal structures, with their core advantages of high strength, corrosion resistance, and fatigue resistance, are extensively used in the core load-bearing structures of critical equipment such as pipeline systems, pressure vessels, storage tank bodies, flange joints, and valve assemblies. During the manufacturing, processing, and long-term operation and maintenance of such equipment, rounded corner structures are common in parts, such as the inner transition arc surface of pipe elbows, the rounded transition area at the corners of containers, the rounded corner area of ​​component welds, and the transition arc of flange sealing surfaces. These rounded corner areas are critical stress concentration points in the equipment; their potential defects (such as crack propagation, inclusions, incomplete penetration, and porosity accumulation) directly affect the load-bearing limit and operational safety of the equipment. Failure in these areas can easily lead to major safety accidents such as leaks and explosions. Therefore, it is essential to achieve full-coverage inspection of the rounded corner areas of parts to ensure the inherent safety of industrial production.

[0003] Ultrasonic testing, with its strong penetration, high sensitivity, accurate identification of internal defects, and non-destructive nature, has become one of the core methods for internal quality inspection of metal structural components in the petrochemical and natural gas industries. For the inspection needs of the inner rounded corner areas of these parts, existing technologies still primarily rely on manual scanning. Because the inner rounded corner areas of parts have continuously changing curved surfaces, and some areas are spatially constrained, the inspection process requires operators to manually adjust the incident angle, coupling pressure, and movement trajectory of the ultrasonic probe to attempt to achieve inspection coverage. However, this manual inspection method has significant limitations: firstly, the continuity, irregularity, and spatial constraints of the inner rounded corner surfaces make it difficult to accurately match the coupling state between the ultrasonic probe and the inspection surface, easily leading to blind spots and compromising inspection accuracy and reliability; secondly, the inspection results heavily depend on the operator's professional experience, skill level, and sense of responsibility, resulting in significant human error and the inability to form a standardized, traceable inspection data chain, which is detrimental to quality control and data traceability during the inspection process, and fails to meet the development needs of the petrochemical and natural gas industries for digital and intelligent equipment manufacturing and maintenance inspections. Summary of the Invention

[0004] The purpose of this invention is to provide an ultrasonic testing device and a method for ultrasonic testing of the inner fillet of parts, so as to solve the technical problems of low accuracy, large interference from human factors, and difficulty in achieving full coverage scanning in the prior art.

[0005] In a first aspect, an ultrasonic testing device for the inner fillet radius of a part is provided, comprising: a support component, an adjustable-angle ultrasonic testing mechanism, and an angle indicating mechanism; the support component has an outer contour tangent to the cross-sectional contour of the region of the inner fillet radius of the part to be inspected and a first sidewall arranged perpendicular to the cross-section, the first sidewall having a first groove, the first groove being a first arc groove, the first arc groove being configured such that its center coincides with the center of the inner fillet radius of the part to be inspected and its arc length meets the angle adjustment requirements of the adjustable-angle ultrasonic testing mechanism; the adjustable-angle ultrasonic testing mechanism is disposed on the side of the first sidewall and includes a wedge, an ultrasonic probe, and a sliding sleeve housing connected sequentially from the inside to the outside along the radial direction of the inner fillet radius of the part to be inspected. The ultrasonic probe is acoustically coupled to the inner rounded corner surface of the part under test via the wedge block at one end, and is radially movably connected to the sliding sleeve housing at the other end. The radial pressing mechanism is used to drive the ultrasonic probe to apply radial pressure to the inner rounded corner surface of the part under test. The sliding sleeve housing is installed on the side of the first sidewall and can move and be fixed along the arc direction of the first slot, thereby realizing the angle adjustment of the adjustable angle ultrasonic testing mechanism. The angle indicating mechanism is disposed on the outer side of the first sidewall and passes through the first slot and is fixedly connected to the sliding sleeve housing, and can indicate the position of the angle indicating scale of the adjustable angle ultrasonic testing mechanism relative to the outer side surface of the first sidewall.

[0006] As an optimization and / or instantiation of the ultrasonic testing device for the inner fillet of the above-mentioned parts, further: the arc of the first arc groove is symmetrically arranged along the angle bisector of the inner fillet of the part to be inspected.

[0007] As an optimization and / or instantiation of the ultrasonic testing device for the inner radius of the aforementioned parts, further: the sliding sleeve housing is slidably engaged with the first groove through a sliding groove positioning key mounted on the sliding sleeve housing, the sliding groove positioning key having arc-shaped edges respectively adapted to the inner and outer arc edges of the first arc groove; the angle indicating mechanism includes an angle adjusting plate, the angle adjusting plate being connected to the sliding groove positioning key, thereby enabling the angle adjusting plate to move synchronously with the sliding groove positioning key, the angle adjusting plate being provided with a second arc groove, and when the angle adjusting plate moves synchronously with the sliding groove positioning key, the angle adjusting plate can always be locked onto the first sidewall by a locking nut passing through the second arc groove.

[0008] As an optimization and / or instantiation of the ultrasonic testing device for the inner fillet of the above-mentioned parts, the supporting component further includes a second sidewall disposed opposite to the first sidewall, and the adjustable angle ultrasonic testing mechanism is disposed between the first sidewall and the second sidewall.

[0009] As an optimization and / or instantiation of the ultrasonic testing device for the inner fillet of the above-mentioned parts, further: a second slot is provided on the second sidewall, the second slot allowing the protruding part on the adjustable angle ultrasonic testing mechanism to extend out of the second sidewall through the second slot.

[0010] As an optimization and / or instantiation of the above-mentioned ultrasonic testing device for inner fillet corners of parts, further: the radial clamping mechanism includes a clamping lock nut, a compression spring, and a clamping screw; the clamping lock nut is installed at the end of the sliding sleeve housing, the clamping screw is installed in the clamping lock nut, and the compression spring is sleeved on the clamping screw, for providing a preload force to the ultrasonic probe pointing towards the inner fillet corner surface of the part to be inspected under the axial pressure of the clamping screw.

[0011] As an optimization and / or instantiation of the ultrasonic testing device for the inner fillet radius of the aforementioned parts, further: the ultrasonic probe includes a piezoelectric crystal, a backing damping material, and an insulating shell arranged sequentially from the inside out; a miniature threaded coaxial connector is provided on the side of the ultrasonic probe; a sliding sleeve housing slot is provided on the sliding sleeve housing, and the miniature threaded coaxial connector slidably passes through the sliding sleeve housing slot; the thickness of the piezoelectric crystal is equal to half the propagation wavelength of the ultrasonic wave in the piezoelectric crystal; the width of the wedge root is the same as the diameter of the piezoelectric crystal.

[0012] As an optimization and / or instantiation of the ultrasonic testing device for the inner fillet of the above-mentioned parts, the ultrasonic probe is further mounted on the outer shell of the sliding sleeve via a sliding sleeve lock nut.

[0013] As an optimization and / or instantiation of the ultrasonic testing device for the inner fillet of the above-mentioned parts, further: taking the angle bisector of the inner fillet of the part to be tested as the zero-degree reference line, the angle adjustment range of the adjustable angle ultrasonic testing mechanism covers the range of ±15° of the zero-degree reference line.

[0014] Secondly, an ultrasonic testing method for the inner fillet of a part is provided, using the ultrasonic testing device for the inner fillet of a part described in the first aspect, and comprising the following steps: 1) determining the center frequency and diameter of the ultrasonic probe based on the acoustic attenuation and thickness of the material in the inner fillet region of the part to be tested; 2) confirming the angle adjustment range of the adjustable angle ultrasonic testing mechanism based on the radius of the inner fillet of the part to be tested; 3) performing finite element simulation of the ultrasonic testing of the inner fillet by combining the center frequency, the diameter, and the angle adjustment range to determine the length of the wedge, so as to significantly suppress the reflected noise generated by the sound wave at the boundary of the wedge and achieve the optimal signal-to-noise ratio of the echo signal in the detection area; 4) sequentially placing the wedge, the ultrasonic probe, and the sliding sleeve... 5) Assemble the outer shell and the radial clamping mechanism to complete the fabrication of the adjustable angle ultrasonic testing mechanism; 6) Install the assembled adjustable angle ultrasonic testing mechanism onto the support component; 7) Drive the adjustable angle ultrasonic testing mechanism to slide along the first slot to a preset angle, fix the adjustable angle ultrasonic testing mechanism, and use the radial clamping mechanism to radially press and adhere the wedge block to the inner rounded corner surface of the part to be inspected; 8) Press the support component to make it adhere tightly to the part to be inspected, and slide it along the axial direction of the part to complete the scanning and inspection of the inner rounded corner area at the preset angle; 9) Repeat steps 6) to 7) to change the angle of the adjustable angle ultrasonic testing mechanism to perform multi-angle scanning and achieve full coverage inspection of the inner rounded corner area.

[0015] The ultrasonic testing device and method for the inner fillet radius of parts described above have the following beneficial effects:

[0016] First, by setting a first arc groove on the first side wall of the support component, and the center of the first arc groove coincides with the center of the inner round corner of the part to be inspected, the adjustable angle ultrasonic testing mechanism can adjust the angle around the center of the inner round corner of the part to be inspected. With the help of a wedge, acoustic coupling between the ultrasonic probe and the surface to be inspected is achieved (the wedge is set between the ultrasonic probe and the inner round corner surface of the part to be inspected, serving as an intermediate medium for sound wave transmission, so that the sound waves emitted by the ultrasonic probe can be effectively transmitted to the inner round corner area of ​​the part to be inspected), ensuring that the incident sound beam can fully cover the inner round corner area of ​​the part, thus solving the problem of blind spots that are easy to occur in the existing manual inspection method.

[0017] Secondly, by applying stable radial pressure to the ultrasonic probe through the radial clamping mechanism, the wedge is ensured to fit tightly against the inner rounded corner surface of the part to be inspected, eliminating the influence of uneven manual pressing on the coupling state and signal quality, and improving the detection accuracy and reliability.

[0018] Third, by using the angle indicator mechanism to indicate the angle position of the adjustable-angle ultrasonic testing mechanism in real time, the quantitative control of the testing angle is realized, making the testing process standardized and traceable, improving the repeatability of the testing results, and facilitating the quality control and traceability management of the testing data.

[0019] Fourth, the support component adopts an outer contour design that is tangent to the cross-sectional contour of the inner rounded corner area of ​​the part to be inspected. For parts of different sizes, only the support component with the corresponding external dimensions needs to be replaced to adapt it. There is no need to redesign the entire inspection device, which effectively improves the versatility and design efficiency of the tooling.

[0020] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. Additional aspects and advantages provided by the present invention will be set forth in part in the description which follows, and in part will be obvious from the description or may be learned by practice. Attached Figure Description

[0021] The accompanying drawings, which form part of this specification, are used to aid in understanding the invention. The contents provided in the drawings and their related descriptions in this specification can be used to explain the invention, but do not constitute an undue limitation of the invention.

[0022] Figure 1 This is a schematic diagram illustrating the working principle of an embodiment of the ultrasonic testing device for inner fillet corners of parts according to the present invention.

[0023] Figure 2 This is a three-dimensional view of the ultrasonic testing device for the inner fillet radius of the aforementioned parts.

[0024] Figure 3 This is an exploded view of the ultrasonic testing device for the inner fillet radius of the aforementioned parts.

[0025] Figure 4 This is an exploded view of the adjustable angle ultrasonic testing mechanism in the ultrasonic testing device for the inner fillet radius of the aforementioned parts.

[0026] Figure 5 This is a structural diagram of the ultrasonic probe in the ultrasonic testing device for the inner fillet radius of the aforementioned parts.

[0027] Figure 6 This is a schematic diagram of the sliding motion of the ultrasonic testing device for the inner fillet radius of the aforementioned parts when testing an I-beam.

[0028] Figure 7 This is a schematic diagram of the angle adjustment range of the ultrasonic testing device for the inner fillet radius of the aforementioned parts.

[0029] Figure 8 This is a schematic diagram of the angle adjustment range required for testing.

[0030] Figure 9 This is a schematic diagram showing the angle adjustment of the ultrasonic testing device for the inner radius of the aforementioned parts when testing an I-beam.

[0031] Figure 10 This is a finite element simulation diagram of the acoustic beam incident area of ​​the wedge block in the inner corner region of the ultrasonic testing device for the inner corner of the aforementioned part.

[0032] Figure 11 This is a schematic diagram of the sound beam incident area when performing variable angle detection of inner rounded corners.

[0033] Figure 12 This is a schematic diagram of the assembly of an adjustable-angle ultrasonic testing mechanism.

[0034] Figure 13 The results are finite element simulation comparisons of the ultrasonic signal amplitude of the ultrasonic testing device for the inner fillet radius of the aforementioned parts under different wedge lengths.

[0035] The following components are marked in the diagram: support component 100; adjustable angle ultrasonic testing mechanism 200; angle indicating mechanism 300; first slot 101; second slot 102; sliding sleeve housing 210; sliding sleeve housing slot 211; sliding sleeve lock nut 212; radial clamping mechanism 220; compression spring 221; clamping lock nut 222; clamping screw 223; ultrasonic probe 230; miniature threaded coaxial connector 231; insulating housing 232; backing damping material 233; piezoelectric crystal 234; wedge block 240; sliding groove positioning key 201; locking nut 301; angle adjusting plate 302; angle indicating scale 303. Detailed Implementation

[0036] The present invention will now be clearly and completely described in conjunction with the accompanying drawings. Those skilled in the art will be able to implement the present invention based on these descriptions. Before describing the present invention in conjunction with the accompanying drawings, it should be particularly noted that:

[0037] The technical solutions and features provided in the various sections, including the following description, can be combined with each other without conflict. Furthermore, where possible, these technical solutions, features, and related combinations can be given specific technical subject matter and protected by relevant patents.

[0038] The embodiments of the present invention described below are generally only some embodiments and not all embodiments. Based on these embodiments, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of patent protection.

[0039] The terms "comprising," "including," "having," and any variations thereof in this specification, the corresponding claims, and related sections are intended to cover non-exclusive inclusion. Other related terms and units can be reasonably interpreted based on the relevant content provided in this specification.

[0040] like Figures 1 to 3 As shown, the ultrasonic testing device for inner rounded corners of a part provided in this embodiment of the invention includes a support component 100, an adjustable-angle ultrasonic testing mechanism 200, and an angle indicating mechanism 300. This ultrasonic testing device for inner rounded corners of a part is used for ultrasonic non-destructive testing of the inner rounded corner area of ​​a part.

[0041] The support component 100 serves as the basic frame of the entire device, providing a mounting base for the adjustable-angle ultrasonic testing mechanism 200 and the angle indicating mechanism 300. The support component 100 has an outer contour tangent to the cross-sectional contour of the area of ​​the inner rounded corner of the part to be inspected. This outer contour design allows the support component 100 to stably conform to the surface of the part to be inspected, ensuring the stability of the device position during the inspection process. The support component 100 also has a first sidewall arranged perpendicular to the cross-section, on which a first slot 101 is provided. The first slot 101 is a first arcuate groove, configured such that its center coincides with the center of the inner rounded corner of the part to be inspected (see [reference]). Figure 7 The arc length corresponds to the angle adjustment range required by the adjustable angle ultrasonic testing mechanism 200. Through this design of coincident centers, the adjustable angle ultrasonic testing mechanism 200 can rotate and adjust around the center of the inner radius of the part to be inspected, thereby achieving accurate detection of different positions of the inner radius.

[0042] like Figures 2-4 As shown, the adjustable-angle ultrasonic testing mechanism 200 is disposed on the side of the first sidewall and includes a wedge block 240, an ultrasonic probe 230, a sliding sleeve housing 210, and a radial pressing mechanism 220 connected sequentially from the inside to the outside along the radial direction of the inner rounded corner of the part to be inspected. One end of the ultrasonic probe 230 is acoustically coupled to the inner rounded corner surface of the part to be inspected through the wedge block 240, and the other end is radially movably connected to the sliding sleeve housing 210. The radial pressing mechanism 220 is used to drive the ultrasonic probe 230 to apply radial pressure to the inner rounded corner surface of the part to be inspected, ensuring that the wedge block 240 is in close contact with the surface to be inspected. The sliding sleeve housing 210 is mounted on the side of the first sidewall and can move and be fixed along the arc direction of the first slot 101, thereby realizing the angle adjustment of the adjustable-angle ultrasonic testing mechanism 200.

[0043] An angle indicating mechanism 300 is disposed on the outer side of the first sidewall and is fixedly connected to the sliding sleeve housing 210 through the first slot 101. It can indicate the position of the angle indicating scale 303 of the adjustable angle ultrasonic testing mechanism 200 relative to the outer side surface of the first sidewall. Through the angle indicating mechanism 300, the operator can accurately read the current testing angle, improving the repeatability and standardization of the testing results.

[0044] In a preferred embodiment of the present invention, the arc of the first circular groove is symmetrically arranged along the angle bisector of the inner fillet of the part to be inspected. For example... Figure 7 and Figure 8 As shown, the bisector of the inner fillet of the part to be inspected is taken as the zero-degree reference line, and the first arc groove is symmetrically distributed on both sides of this reference line. This symmetrical design has the following advantages: on the one hand, it allows the adjustable-angle ultrasonic testing mechanism 200 to adjust the angle within the same range on both sides of the bisector, facilitating symmetrical scanning of the inner fillet area; on the other hand, it simplifies the calibration and reading of the angle indicator scale 303, allowing the operator to intuitively determine the direction and magnitude of the current testing angle offset relative to the zero-degree reference line.

[0045] like Figure 3 As shown, the sliding sleeve housing 210 slides into the first groove 101 via a sliding groove positioning key 201 mounted on the sliding sleeve housing 210. The sliding groove positioning key 201 has arc-shaped edges that respectively match the inner and outer arc edges of the first arc groove. This matching design ensures that the sliding groove positioning key 201 can slide smoothly along the first arc groove, while preventing radial wobbling and ensuring the stability of the ultrasonic probe 230 position during the detection process.

[0046] The angle indicating mechanism 300 includes an angle adjusting plate 302, which is connected to a sliding positioning key 201, allowing the angle adjusting plate 302 to move synchronously with the sliding positioning key 201. The angle adjusting plate 302 has a second arcuate groove. When the angle adjusting plate 302 moves synchronously with the sliding positioning key 201, it is always locked to the first side wall by a locking nut 301 passing through the second arcuate groove. When the detection angle needs to be adjusted, the locking nut 301 is loosened, the angle adjusting plate 302 is pushed to slide the sliding positioning key 201 along the first groove 101 to the desired angle position, and then the locking nut 301 is tightened to fix the adjustable angle ultrasonic testing mechanism 200 at that angle position. This locking mechanism is simple in structure, easy to operate, and provides a reliable fixing effect.

[0047] In a preferred embodiment of the invention, the support member 100 further has a second sidewall disposed opposite to the first sidewall, and the adjustable-angle ultrasonic testing mechanism 200 is disposed between the first sidewall and the second sidewall. The double-sidewall structure provides better support and protection for the adjustable-angle ultrasonic testing mechanism 200, while enhancing the structural rigidity and stability of the entire device.

[0048] Furthermore, a second slot 102 is provided on the second sidewall, which allows the protruding portion of the adjustable-angle ultrasonic testing mechanism 200 to extend out of the second sidewall through the second slot 102. For example... Figure 2 and Figure 3As shown, the second slot 102 provides a space for larger components on the adjustable angle ultrasonic testing mechanism 200 (such as part of the radial clamping mechanism 220 or the miniature threaded coaxial connector 231 described below), avoiding interference with the second sidewall and ensuring that the adjustable angle ultrasonic testing mechanism 200 can be smoothly adjusted within the full angle range.

[0049] like Figure 4 and Figure 12 As shown, the radial clamping mechanism 220 includes a clamping lock nut 222, a compression spring 221, and a clamping screw 223. The clamping lock nut 222 is installed at the end of the sliding sleeve housing 210, the clamping screw 223 is installed in the clamping lock nut 222, and the compression spring 221 is sleeved on the clamping screw 223, which is used to provide a preload force to the ultrasonic probe 230 pointing towards the inner rounded corner surface of the part to be inspected under the axial pressure of the clamping screw 223.

[0050] In practical use, the compression of the compression spring 221 can be adjusted by rotating the clamping screw 223, thereby controlling the amount of preload applied to the ultrasonic probe 230. This elastic preload design is of great significance: the compression spring 221 can provide stable and uniform pressure, ensuring that the wedge 240 fits tightly against the inner rounded corner surface of the part to be inspected, eliminating the problem of uneven pressure when manually pressing; at the same time, the elastic preload can also adapt to the slight unevenness of the surface to be inspected or the surface undulation changes during axial sliding, ensuring the consistency of acoustic coupling during the detection process, thereby improving the quality and stability of the detection signal.

[0051] like Figure 5 As shown, the ultrasonic probe 230 includes a piezoelectric crystal 234, a backing damping material 233, and an insulating shell 232 arranged sequentially from the inside out. A miniature threaded coaxial connector 231 (e.g., a C5 connector) is provided on the side of the ultrasonic probe 230. The piezoelectric crystal 234 is the core component of the ultrasonic probe 230, used to convert electrical signals into ultrasonic waves and to convert received ultrasonic echoes into electrical signals. The backing damping material 233 is located on the back of the piezoelectric crystal 234, used to absorb the ultrasonic energy radiated backward by the piezoelectric crystal 234, reducing noise interference and improving the axial resolution of the signal. The insulating shell 232 encloses the external components, serving to protect the internal components and provide electrical insulation. The miniature threaded coaxial connector 231 is used to connect a signal transmission cable, enabling signal transmission between the ultrasonic probe 230 and external ultrasonic testing equipment.

[0052] The sliding sleeve housing 210 is provided with a sliding sleeve housing slot 211, through which the miniature threaded coaxial connector 231 slidably passes. This design allows the ultrasonic probe 230 to slide radially relative to the sliding sleeve housing 210, and with the elastic pre-tightening of the radial clamping mechanism 220, adaptive adjustment for different contact depths can be achieved.

[0053] In the design of the piezoelectric crystal 234, the thickness of the piezoelectric crystal 234 is equal to half the propagation wavelength of the ultrasonic wave within it. This design conforms to the resonance condition of the piezoelectric transducer, enabling the piezoelectric crystal 234 to generate maximum electromechanical conversion efficiency at the operating frequency, thereby improving the sensitivity of the ultrasonic probe 230.

[0054] This invention utilizes an adjustable angle structure to achieve full coverage detection of the inner rounded corner area. Its core lies in the sound beam incident path formed by the adjustable angle, the ultrasonic probe 230, and the wedge 240 (see...). Figure 11 The specific physical principle is as follows: Assume the sound velocities of the ultrasonic waves in the wedge 240 and the inner rounded corner (R region) are c1 and c2, respectively. When the sound beam passes through the wedge 240, it converges at the wedge-R region interface, forming the sound beam focus q0. The sound beam divergence angle α2 in the R region is calculated by Snell's law, with the formula: α2 = arcsin[(c2 / c1) * sinα1], where α1 is the incident angle of the sound beam in the wedge 240. By selecting a suitable wedge material, c2 is made greater than c1, thus α2 is greater than α1. Based on this, since the angle adjustment range of the adjustable angle ultrasonic testing mechanism 200 covers the positive and negative φ region of the zero-degree baseline (preferably within ±15 degrees), combined with the physical divergence characteristics of the sound beam inside the part, the actual coverage area of ​​the sound beam is further increased, thereby ensuring full coverage scanning and detection of the inner rounded corner region of the part.

[0055] The wedge 240 is made of plexiglass, and the width of its root is the same as the diameter of the piezoelectric crystal 234. The plexiglass material has moderate acoustic impedance, enabling acoustic impedance matching between the piezoelectric crystal 234 and the material of the part under test, reducing interface reflection loss and improving acoustic energy transfer efficiency. The design that the root width of the wedge 240 is the same as the diameter of the piezoelectric crystal 234 ensures effective ultrasonic energy transfer and avoids energy waste.

[0056] Specifically, the wedge 240 is a conical structure made of plexiglass, including a root end face connected to the ultrasonic probe 230 and a conical surface that contacts the inner rounded corner surface of the part under inspection. The root end face is a circular plane used for acoustic coupling with the piezoelectric crystal 234. The root width, i.e., the diameter of the root end face, is the same as the diameter of the piezoelectric crystal 234 to ensure complete transmission of ultrasonic energy. The wedge length refers to the distance from the root end face to the apex of the conical surface along the conical axis. This length is determined through finite element simulation optimization to significantly suppress reflection clutter generated by the sound wave at the wedge boundary and to achieve the optimal signal-to-noise ratio of the echo signal in the detection area. The plexiglass material has moderate acoustic impedance, enabling acoustic impedance matching between the piezoelectric crystal 234 and the material of the part under inspection, reducing interface reflection loss, and improving acoustic energy transmission efficiency.

[0057] Figure 13 This is a comparison of finite element simulation results of the ultrasonic signal amplitude of the ultrasonic testing device for the inner fillet corner of the aforementioned part under different wedge lengths. The horizontal axis in the figure represents time in μs, and the vertical axis represents the ultrasonic signal amplitude in arb. (arbitrary unit). The figure shows the ultrasonic signal waveforms for four cases where the wedge 240 length is 4.75mm, 5mm, 5.25mm, and 5.5mm. It can be seen from the figure that surface reflection waves appear between approximately 0 and 1 μs, and triangular region reflection waves appear between approximately 5 and 7 μs. As the length of the wedge 240 increases, the arrival time of the triangular region reflection waves is slightly delayed, which is due to the increased propagation path of the ultrasonic wave within the longer wedge 240. This simulation result shows that by adjusting the length of the wedge 240, the adjustable-angle ultrasonic testing mechanism 200 can effectively detect defect reflection signals in the triangular region of the inner fillet corner.

[0058] The ultrasonic probe 230 is mounted on the sliding sleeve housing 210 via the sliding sleeve lock nut 212. For example... Figure 4 and Figure 12 As shown, the sliding sleeve lock nut 212 is disposed on the sliding sleeve housing 210 and is used to limit the ultrasonic probe 230 within the sliding sleeve housing 210. An appropriate fitting clearance is maintained between the sliding sleeve lock nut 212 and the ultrasonic probe 230, allowing the ultrasonic probe 230 to slide radially under the action of the radial clamping mechanism 220, while preventing the ultrasonic probe 230 from detaching from the sliding sleeve housing 210. This installation method is compact, easy to assemble and disassemble, and facilitates the replacement and maintenance of the ultrasonic probe 230.

[0059] like Figures 7 to 9 As shown, with the angle bisector of the inner fillet of the part under inspection as the zero-degree reference line, the angle adjustment range of the adjustable-angle ultrasonic testing mechanism 200 covers ±15° of the zero-degree reference line, i.e., the total angle adjustment range is 30°. This angle adjustment range is determined based on the following considerations: for a typical 90° inner fillet structure, a ±15° adjustment range can cover the main inspection requirements of the inner fillet area; simultaneously, this range takes into account the influence of the ultrasonic incident angle on the inspection effect, avoiding signal attenuation and blind spots caused by excessively large incident angles.

[0060] like Figure 8 As shown, the angle adjustment range φ can be calculated and determined based on the radius of the inner fillet of the part to be inspected and the dimensions of the wedge 240. Let the inner fillet radius be Rm and the effective detection length of the wedge 240 be L0. Theoretically, the angle adjustment range should satisfy the following: when adjusted from the zero-degree position to both sides, the sound beam incident area of ​​the wedge 240 can cover the entire inner fillet arc surface. In practical applications, the angle adjustment range can be appropriately adjusted according to the specific structural parameters of the part.

[0061] Figure 10This is a finite element simulation diagram of the acoustic beam incident area of ​​the wedge block in the inner corner region of the ultrasonic testing device for the inner corner of the aforementioned part. Figure 10 The upper figure shows the velocity distribution at time 8E-7s, and the lower figure shows the velocity distribution at time 1.5E-6s. As can be seen from the figures, the ultrasonic waves emitted by the ultrasonic probe 230 are refracted by the wedge 240 and then incident on the part under inspection at a certain angle. The ultrasonic waves propagate in the plate and ribs of the T-shaped structure. The velocity magnitude is displayed by the color code on the right, in m / s, with a value range of ×10. 4 The magnitude of the sound beam propagation is shown in the image above. Comparing the two images, the top image represents the initial stage of sound beam propagation, where the ultrasonic wave has just entered the inner rounded corner area of ​​the part under inspection. The bottom image represents the later stage of sound beam propagation, where the ultrasonic wave has fully diffused inside the part under inspection and covered the inner rounded corner and adjacent areas. This simulation result verifies that the adjustable-angle ultrasonic testing mechanism 200 can achieve the function of obliquely incident ultrasonic wave testing, and the sound beam can effectively cover the inner rounded corner testing area.

[0062] The present invention also provides an ultrasonic testing method for the inner fillet radius of a part, which uses the above-mentioned ultrasonic testing device for the inner fillet radius of a part and includes the following steps:

[0063] Step 1) Determine the center frequency and diameter of the ultrasonic probe 230 based on the acoustic attenuation and thickness of the material in the rounded corner area of ​​the part to be inspected.

[0064] Specifically, the acoustic attenuation characteristics vary depending on the material of the rounded corner area of ​​the part under inspection. For materials with high acoustic attenuation, a lower center frequency should be selected to ensure sufficient penetration depth; for materials with low acoustic attenuation, a higher center frequency can be selected to obtain better detection resolution. Simultaneously, the thickness of the area under inspection also affects the selection of the center frequency; thicker areas require a lower center frequency. The diameter of the ultrasonic probe 230 needs to be determined by comprehensively considering factors such as detection resolution, beam coverage, and the size of the rounded corner.

[0065] Step 2) Based on the radius of the inner fillet of the part to be inspected, confirm the angle adjustment range of the adjustable angle ultrasonic testing mechanism 200.

[0066] like Figure 7 and Figure 8 As shown, the smaller the inner corner radius Rm, the larger the angle adjustment range required to achieve full coverage detection. Based on the geometric relationship between the inner corner radius Rm and the effective detection length L0 of the wedge 240, the minimum required angle adjustment range can be calculated. When determining the angle adjustment range, an appropriate margin should be allowed to ensure sufficient overlap of the detection areas and avoid missed detections.

[0067] Step 3) Combine the center frequency, the diameter and the angle adjustment range to perform finite element simulation of ultrasonic testing of inner rounded corners, determine the length of wedge 240, so as to significantly suppress the reflected noise generated by the sound wave at the boundary of wedge 240 and make the signal-to-noise ratio of the echo signal in the detection area reach the optimal state.

[0068] like Figure 10 , Figure 11 and Figure 13 As shown, the length of wedge 240 has a significant impact on the detection effect. When wedge 240 is too short, the reflected clutter generated by the sound wave at the wedge boundary will interfere with the detection signal and reduce the signal-to-noise ratio; when wedge 240 is too long, the propagation attenuation of the sound wave in the wedge increases, which will also reduce the detection signal strength. Through finite element simulation, the sound field distribution and echo signal characteristics under different wedge lengths can be simulated, thereby determining the optimal wedge length. Figure 13 The results of finite element simulations comparing the ultrasonic signal amplitudes under different wedge lengths are shown. It can be seen that there is an optimal wedge length that achieves the best signal-to-noise ratio.

[0069] Step 4) Assemble the wedge 240, ultrasonic probe 230, sliding sleeve housing 210 and radial clamping mechanism 220 in sequence to complete the fabrication of the adjustable angle ultrasonic testing mechanism 200.

[0070] like Figure 12 As shown, the assembly process is performed sequentially: First, connect the wedge 240 to the front end of the ultrasonic probe 230 (using methods such as adhesive bonding or threaded connection); then, insert the ultrasonic probe 230 with the wedge 240 installed into the sliding sleeve housing 210, and limit its position using the sliding sleeve lock nut 212; finally, install the clamping lock nut 222 at the end of the sliding sleeve housing 210, fit the compression spring 221 onto the clamping screw 223, and screw the clamping screw 223 into the clamping lock nut 222. After assembly, adjust the clamping screw 223 to bring the compression spring 221 to an appropriate pre-compression state.

[0071] Step 5) Install the assembled adjustable angle ultrasonic testing mechanism 200 onto the support component 100.

[0072] Specifically, the sliding positioning key 201 is aligned with the first slot 101 and inserted, allowing the sliding positioning key 201 to slide in conjunction with the first arc groove; then, the angle adjusting plate 302 is connected to the sliding positioning key 201, and the locking nut 301 is installed onto the first side wall through the second arc groove on the angle adjusting plate 302. After installation, the adjustable angle ultrasonic testing mechanism 200 can be angled along the first slot 101.

[0073] Step 6) Drive the adjustable angle ultrasonic testing mechanism 200 to slide along the first slot 101 to the preset angle, then fix it by locking nut 301, and use clamping screw 223 to radially press and adhere the wedge block 240 to the inner rounded corner surface of the part to be inspected.

[0074] According to the testing requirements, loosen the locking nut 301, push the angle adjustment plate 302 to slide the adjustable angle ultrasonic testing mechanism 200 to the preset angle position (determined by reading the angle indicator scale 303), and then tighten the locking nut 301 to fix it. Next, rotate the clamping screw 223 to apply a preload force to the ultrasonic probe 230 by compressing the spring 221, driving the wedge 240 to fit tightly against the inner rounded corner surface of the part to be inspected. When performing acoustic coupling, an appropriate amount of coupling agent can be applied between the wedge 240 and the surface to be inspected to improve the sound energy transmission efficiency.

[0075] Step 7) Press the support component 100 to make it fit tightly against the part to be inspected, and slide it along the axial direction of the part to complete the scanning and inspection of the inner rounded corner area at the preset angle.

[0076] like Figure 6 As shown, taking the inspection of an I-beam as an example, the outer contour of the support component 100 is fitted onto the surface of the part to be inspected. The operator holds the support component 100 and presses it appropriately to ensure close contact with the part. Then, it slides at a uniform speed along the axial direction of the part (i.e., the direction perpendicular to the cross-section of the inner fillet), while the ultrasonic testing equipment records the detection signal. Through this axial scanning method, a complete inspection of the inner fillet area at the current preset angle can be completed.

[0077] Step 8) Repeat steps 6) to 7) to change the angle of the adjustable-angle ultrasonic testing mechanism 200 to perform multi-angle scanning and achieve full coverage detection of the inner rounded corner area.

[0078] like Figure 9 As shown, after completing an axial scan at one angle, loosen the locking nut 301, adjust the adjustable angle ultrasonic testing mechanism 200 to the next angle position, and perform an axial scan again. Change the testing angle sequentially until the entire angle adjustment range is covered. The angle interval for multi-angle scans should be determined based on the effective detection area width of the wedge block 240 to ensure appropriate overlap between adjacent angle detection areas and avoid missed detection areas. Through multi-angle scanning, full coverage detection of the inner rounded corner area can be achieved, effectively detecting various defects within the inner rounded corner area.

[0079] like Figure 1As shown, the working principle of the ultrasonic testing device for inner rounded corners of the present invention is as follows: The support component 100 is stably attached to the surface of the part to be tested by its outer contour, which is tangent to the cross-sectional contour of the inner rounded corner, providing a stable foundation for testing. The center of the first arc groove coincides with the center of the inner rounded corner of the part to be tested, allowing the adjustable angle ultrasonic testing mechanism 200 to be rotated and adjusted around the center of the inner rounded corner. By adjusting the angular position of the adjustable angle ultrasonic testing mechanism 200, the angle at which the ultrasonic wave is incident on the surface of the inner rounded corner can be changed, thereby enabling the testing of different areas of the inner rounded corner.

[0080] The design of the wedge 240 allows ultrasonic waves to be incident at a suitable angle on the inner rounded corner surface of the part to be inspected. After the sound waves enter the interior of the part, they are reflected at the defect or the bottom surface. The reflected echo is transmitted back to the ultrasonic probe 230 via the wedge 240 and converted into an electrical signal. By analyzing the amplitude, time, and other characteristics of the echo signal, it is possible to determine whether there is a defect in the area to be inspected, as well as the location and size of the defect.

[0081] The compression spring 221 of the radial clamping mechanism 220 provides a stable preload, ensuring that the wedge 240 fits tightly against the surface to be inspected, eliminating the impact of uneven manual pressing force on the quality of the detection signal. The angle indicating mechanism 300 enables quantitative indication of the detection angle, making the detection process traceable and repeatable, and improving the standardization level of the detection.

[0082] The ultrasonic testing device for inner fillet corners of parts of the present invention has the following advantages: By setting a first arc groove whose center coincides with the center of the inner fillet corner, the adjustable angle ultrasonic testing mechanism can rotate precisely around the center of the inner fillet corner. Combined with the reasonable design of the wedge block, it ensures that the incident sound beam can fully cover the inner area of ​​the inner fillet corner of the part; the compression spring of the radial pressing mechanism provides a constant preload, ensuring that the wedge block is in close contact with the surface to be inspected, eliminating the influence of uneven manual pressing on signal quality; the angle indicating mechanism quantifies the detection angle, improving the repeatability of the detection results; for parts of different sizes, only the outer dimensions of the support component need to be updated to adapt, effectively improving the efficiency of tooling design.

[0083] The specific embodiments of the present invention have been described in detail above, but the present invention is not limited to the specific embodiments described above, which are merely exemplary. For those skilled in the art, any equivalent modifications and substitutions to this invention are also within the scope of the present invention. Therefore, all equivalent transformations and modifications made without departing from the spirit and scope of the present invention should be covered within the scope of the present invention.

Claims

1. An ultrasonic testing device for the inner fillet radius of a part, characterized in that: include: Support component (100), adjustable angle ultrasonic testing mechanism (200), and angle indicating mechanism (300); The support member (100) has an outer contour tangent to the cross-sectional contour of the area of ​​the inner rounded corner of the part to be inspected and a first sidewall arranged perpendicular to the cross-section. The first sidewall is provided with a first slot (101). The first slot (101) is a first arc groove. The first arc groove is configured such that its center coincides with the center of the inner rounded corner of the part to be inspected and its arc length corresponds to the angle adjustment range required by the adjustable angle ultrasonic testing mechanism (200). The adjustable-angle ultrasonic testing mechanism (200) is disposed on the side of the first sidewall and includes a wedge (240), an ultrasonic probe (230), a sliding sleeve housing (210), and a radial pressing mechanism (220) connected sequentially from the inside to the outside along the radial direction of the inner rounded corner of the part to be inspected; one end of the ultrasonic probe (230) is acoustically coupled to the inner rounded corner surface of the part to be inspected through the wedge (240), and the other end is radially movably connected to the sliding sleeve housing (210); the radial pressing mechanism (220) is used to drive the ultrasonic probe (230) to apply radial pressure to the inner rounded corner surface of the part to be inspected; the sliding sleeve housing (210) is installed on the side of the first sidewall and can move and be fixed along the arc direction of the first slot (101), thereby realizing the angle adjustment of the adjustable-angle ultrasonic testing mechanism (200); The angle indicating mechanism (300) is disposed on the outer side of the first sidewall and passes through the first slot (101) and is fixedly connected to the sliding sleeve housing (210). It can indicate the position of the adjustable angle ultrasonic detection mechanism (200) relative to the angle indicating scale (303) on the outer side of the first sidewall.

2. The ultrasonic testing device for the inner fillet radius of a part as described in claim 1, characterized in that: The first circular arc groove is symmetrically arranged along the angle bisector of the inner radius of the part to be inspected.

3. The ultrasonic testing device for the inner fillet radius of a part as described in claim 1, characterized in that: The sliding sleeve housing (210) is slidably engaged with the first slot (101) by a sliding groove positioning key (201) installed on the sliding sleeve housing (210). The sliding groove positioning key (201) has arc-shaped edges that are adapted to the inner and outer arc edges of the first arc groove, respectively. The angle indicating mechanism (300) includes an angle adjusting plate (302), which is connected to the sliding groove positioning key (201), so that the angle adjusting plate (302) can move synchronously with the sliding groove positioning key (201). Furthermore, the angle adjusting plate (302) is provided with a second arc groove. When the angle adjusting plate (302) moves synchronously with the sliding groove positioning key (201), the angle adjusting plate (302) can always be locked on the first side wall by a locking nut (301) passing through the second arc groove.

4. The ultrasonic testing device for the inner fillet radius of a part as described in claim 1, characterized in that: The support component (100) also has a second sidewall disposed opposite to the first sidewall, and the adjustable angle ultrasonic testing mechanism (200) is disposed between the first sidewall and the second sidewall.

5. The ultrasonic testing device for the inner fillet radius of a part as described in claim 4, characterized in that: The second sidewall is provided with a second slot (102), which allows the protruding part of the adjustable angle ultrasonic testing mechanism (200) to extend out of the second sidewall through the second slot (102).

6. The ultrasonic testing device for the inner fillet radius of a part as described in claim 1, characterized in that: The radial clamping mechanism (220) includes a clamping lock nut (222), a compression spring (221), and a clamping screw (223). The clamping lock nut (222) is installed at the end of the sliding sleeve housing (210), the clamping screw (223) is installed in the clamping lock nut (222), and the compression spring (221) is sleeved on the clamping screw (223) to provide a preload force to the ultrasonic probe (230) pointing towards the inner rounded corner surface of the part to be inspected under the axial pressure of the clamping screw (223).

7. The ultrasonic testing device for the inner fillet radius of a part as described in claim 1, characterized in that: The ultrasonic probe (230) includes a piezoelectric crystal (234), a backing damping material (233), and an insulating shell (232) arranged sequentially from the inside to the outside. The side of the ultrasonic probe (230) is provided with a miniature threaded coaxial connector (231). The sliding sleeve shell (210) is provided with a sliding sleeve shell slot (211), and the miniature threaded coaxial connector (231) can slide through the sliding sleeve shell slot (211). The thickness of the piezoelectric crystal (234) is equal to half the wavelength of the ultrasonic wave propagating in the piezoelectric crystal (234). The width of the root of the wedge (240) is the same as the diameter of the piezoelectric crystal (234).

8. The ultrasonic testing device for the inner fillet radius of a part as described in claim 1, characterized in that: The ultrasonic probe (230) is mounted on the sliding sleeve housing (210) via the sliding sleeve lock nut (212).

9. The ultrasonic testing device for the inner fillet radius of a part as described in claim 1, characterized in that: The angle bisector of the inner radius of the part to be inspected is taken as the zero-degree reference line, and the angle adjustment range of the adjustable angle ultrasonic testing mechanism (200) covers the range of ±15° of the zero-degree reference line.

10. A method for ultrasonic testing of the inner fillet radius of a part, characterized in that: Using the ultrasonic testing device for the inner fillet radius of a part according to any one of claims 1-9, and comprising the following steps: 1) Determine the center frequency and diameter of the ultrasonic probe (230) based on the acoustic attenuation and thickness of the material in the rounded corner area of ​​the part to be inspected; 2) Determine the angle adjustment range of the adjustable angle ultrasonic testing mechanism (200) based on the radius of the inner fillet of the part to be inspected; 3) Combine the center frequency, the diameter and the angle adjustment range to perform finite element simulation of ultrasonic testing of inner round corners, determine the length of the wedge (240) to significantly suppress the reflected noise generated by the sound wave at the boundary of the wedge (240) and make the signal-to-noise ratio of the echo signal in the detection area reach the optimal state; 4) Assemble the wedge (240), the ultrasonic probe (230), the sliding sleeve housing (210), and the radial clamping mechanism (220) in sequence to complete the fabrication of the adjustable angle ultrasonic testing mechanism (200); 5) Install the assembled adjustable angle ultrasonic testing mechanism (200) onto the support component (100); 6) After driving the adjustable angle ultrasonic testing mechanism (200) to slide along the first slot (101) to a preset angle, fix the adjustable angle ultrasonic testing mechanism (200), and use the radial pressing mechanism (220) to radially press and adhere the wedge (240) to the inner rounded corner surface of the part to be inspected; 7) Press the support component (100) to make it fit tightly against the part to be inspected, and slide it along the axial direction of the part to complete the scanning and inspection of the inner rounded corner area at a preset angle; 8) Repeat steps 6) to 7) to change the angle of the adjustable angle ultrasonic testing mechanism (200) to perform multi-angle scanning and achieve full coverage detection of the inner rounded corner area.

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