Heel Test Block Curved Surface Calibration
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Solution Overview
Problem
There is a lack of standard test blocks for calibrating ultrasonic probes for precision positioning of circumferential oblique defects on curved surfaces in oil and gas drilling equipment, as existing contrast test blocks fail to accurately determine detection angles, scanning speeds, and zero points.
Innovation Solution
A heel test block with a semi-cylinder and flat plates is designed, featuring a circular arc-shaped surface and parallel flat plates of varying thicknesses to facilitate accurate calibration of angles, sound speed, and zero points, with angle scales on the surfaces to detect incidence angles, ensuring precise positioning for ultrasonic flaw detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing contrast test blocks are used for calibration, then the structure is simple and easy to manufacture, but the measurement precision of detection angles, scanning speeds and zero points cannot be ensured for curved surface forged pieces
Solution Approach 1:
The test block incorporates a curved surface (circular arc-shaped surface) that matches the geometry of the forged piece being inspected. This curvature allows the ultrasonic probe to maintain proper contact and alignment with the workpiece surface, enabling accurate measurement of detection angles and positioning of oblique defects on curved surfaces, which flat test blocks cannot provide.
Solution Approach 2:
The test block features different surface geometries in different regions: a curved surface for simulating the forged piece geometry and flat surfaces for stable placement and reference. This local differentiation allows the single test block to serve multiple calibration functions - angle measurement on the curved surface and positional reference on flat surfaces - thereby improving measurement precision without proportionally increasing overall complexity.
2Manufacturing precision
If existing contrast test blocks are used for calibration, then the device complexity is low, but the positioning precision of circumferential oblique defects on curved surfaces cannot be achieved
Solution Approach 1:
The circular arc-shaped surface of the test block replicates the curvature of the forged piece, allowing ultrasonic probes to accurately detect and position oblique defects on curved surfaces. The curved geometry ensures proper sound wave transmission and reflection angles, enabling precise determination of defect locations that match real-world application conditions.
Solution Approach 2:
The test block is pre-configured with specific geometric features (curved surface, flat reference surfaces, dimensional relationships) that establish known reference points and angles before inspection begins. This preliminary setup allows operators to calibrate the ultrasonic equipment and verify positioning accuracy without needing to perform complex calculations or adjustments during the actual inspection process.
3Adaptability or versatility
If a curved surface test block is designed to match forged piece geometry, then the adaptability for curved surface inspection is improved, but the ease of manufacture decreases
Solution Approach 1:
The test block uses a circular arc-shaped surface with a defined radius that matches the geometry of the forged pieces being inspected. This standard curved geometry provides excellent adaptability for inspecting cylindrical or curved components while remaining manufacturable using conventional machining processes such as turning or milling on a lathe, balancing geometric fidelity with manufacturing feasibility.
4Measurement precision
If multiple flat plates of different thicknesses are used for calibration, then the measurement precision of sound speed and zero point is improved, but the device complexity increases
Solution Approach 1:
The test block is divided into multiple flat plates with different thicknesses (e.g., 10mm, 20mm, 30mm) stacked or arranged in sequence. Each plate serves as an independent calibration reference for sound speed and zero point measurements. This segmentation allows operators to perform multiple calibration checks using different path lengths, improving measurement precision and reliability while keeping each individual component simple and easy to manufacture.
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 heel test block enables accurate calibration and positioning of ultrasonic probes for curved surface forged pieces, enhancing the precision of ultrasonic oblique incidence defect detection and improving the detection level of curved surface forged pieces, allowing for effective defect determination and improved fabrication processes.
Implementation Method 1
a line is connected between peak values of a first reflex obtained on a notch between the inner diameter and the outer diameter to establish a datum line of vibration amplitude
Data Source
AI summary
A heel test block comprises a semi-cylinder, a first flat plate and a second flat plate, wherein the side surface of the semi-cylinder comprises a circular arc-shaped surface and a first plane, the first flat plate and the second flat plate are arranged on one side of the first plane, all the parts of the first flat plate have the same thickness, all the parts of the second flat plate have the same thickness, the first flat plate and the second flat plate are arranged in parallel to the first plane, the first flat plate and the second flat plate are arranged on the two sides of the mother line of the semi-cylinder respectively, and the thickness of the first flat plate is less than that of the second flat plate.