Dudou-Shaped Ultrasonic Test Block for Concave Surface Calibration

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Solution Overview

Problem

There is a lack of standard test blocks for calibrating angles, scanning speeds, and zero points in ultrasonic circumferential angle-beam flaw detection on concave forged pieces, which hinders precise positioning and accurate flaw detection in nondestructive testing.

Innovation Solution

A dudou-shaped test block with a testing structure, first and second beam-path structures, and supporting structure is designed, featuring arc-shaped grooves and flat surfaces for precise calibration of angles and acoustic velocities, ensuring accurate placement and minimizing measurement errors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If standard test blocks (boat-shaped or horn-shaped) are used for calibration, then flat surface detection can be performed, but concave surface detection calibration is not possible

Engineering Contradiction:

Improvesurface type adaptabilityVSAvoidcalibration accuracy for concave surfaces

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The test block employs a curved surface structure with a radius of curvature R that matches the concave surface of the workpiece. This curvature adaptation allows the test block to conform to the workpiece geometry, enabling accurate calibration of ultrasonic instruments and probes for concave surface detection where traditional flat-surface test blocks fail.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Measurement precision

If existing reference blocks are used for circumferential angle-beam detection, then basic calibration can be performed, but precise positioning of angles, scanning speeds, and zero points cannot be ensured

Engineering Contradiction:

Improveangle and zero point calibration precisionVSAvoidtest block structure complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The test block is divided into multiple functional regions: a curved surface for angle calibration, a flat surface for zero point calibration, and specific groove structures for scanning speed calibration. This segmentation allows each region to serve a specific calibration purpose, achieving comprehensive precision calibration without requiring an overly complex integrated structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The test block incorporates angular graduations marked on its surfaces, providing visual references for precise angle measurement and calibration. These markings enable operators to accurately determine angular positions during the calibration process, directly improving angle and zero point calibration precision.

Inventive Principle:

Principle #32Color changes

3Adaptability or versatility

If boat-shaped or horn-shaped test blocks are used, then flat surface calibration is achieved, but concave forged piece detection calibration is unavailable

Engineering Contradiction:

Improveworkpiece geometry compatibilityVSAvoidcalibration accuracy for concave geometries

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The test block features a curved surface with a specifically designed radius of curvature that matches the concave geometry of forged pieces. This curvature enables the test block to be placed conformally on concave surfaces, ensuring accurate transmission of ultrasonic waves and precise calibration for detecting flaws in concave geometries.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The test block is designed to serve multiple calibration functions: it can calibrate angles on curved surfaces, establish zero points on flat surfaces, and verify scanning speeds. This multi-functionality makes it a universal calibration tool for various detection scenarios on concave forged pieces, replacing the need for multiple specialized test blocks.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The dudou-shaped test block enables accurate calibration of instruments and probes, facilitating precise ultrasonic flaw location and detection on concave forged pieces by ensuring precise positioning of angles, speeds, and zero points, enhancing the reliability of ultrasonic circumferential angle-beam detection.

Implementation Method 1

ultrasonic circumferential angle-beam flaw detection

Methodology Applied

Scientific EffectUltrasonic wave propagation: Ultrasound

Implementation Method 2

calibrating the angle, acoustic velocity, and zero point

Methodology Applied

Scientific EffectAcoustic velocity calibration: Speed of Sound

Implementation Method 3

first peak values of reflection obtained at notches

Methodology Applied

Scientific EffectUltrasonic reflection: Reflection

Data Source

PatentUS11366084B2Ultrasonic flaw detector test block

Publication Date: 2022.06.21 NANJING DEV ADVANCED MFG

AI summary

A dudou-shaped test block includes a testing structure, a first beam-path structure, and a second beam-path structure. A first arc-shaped groove and a second arc-shaped groove are provided on one side of the testing structure. The other side of the testing structure is a flat surface. The first beam-path structure and the second beam-path structure are both flat plates. A thickness of the first beam-path structure is less than a thickness of the second beam-path structure. The first beam-path structure and the second beam-path structure are both in contact with the flat surface and arranged parallel to the flat surface. The first arc-shaped groove is arranged corresponding to the first beam-path structure, and the second arc-shaped groove is arranged corresponding to the second beam-path structure.