Ultrasonic Interference Fit Connection Force Testing
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Solution Overview
Problem
Current methods for testing the connection force of interference fit parts are unreliable and inefficient, especially in high-load applications like aviation and aerospace, due to the influence of form errors and temperature differences, leading to low prediction accuracy and reduced production efficiency.
Innovation Solution
An ultrasonic testing device comprising an optical table, motion control module, fixture, probe adjustment module, and control loop, which uses a point focusing water immersion probe to measure stress distribution and calculate connection force by transmitting ultrasonic signals through a PC and motion control card, ensuring high accuracy and automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If empirical relationship between connection force and maximum pressing force is used for prediction, then prediction can be obtained, but reliability of prediction result is low due to form error influence
Solution Approach 1:
The patent replaces the empirical mechanical prediction method with an ultrasonic wave-based measurement system. Ultrasonic waves are transmitted through the interference fit part, and the connection force is determined by analyzing the ultrasonic signal characteristics (amplitude, time of flight), eliminating dependence on form errors and pressing force empirical relationships.
Solution Approach 2:
The patent introduces ultrasonic waves as an intermediary to indirectly measure the connection force. Instead of directly measuring pressing force or using empirical relationships, the ultrasonic wave propagation characteristics serve as a mediator that reflects the actual connection state, providing reliable measurement without being affected by form errors.
2Reliability
If each part is tested to meet high connection force requirements, then reliability of connection force measurement is improved, but production efficiency is greatly reduced
Solution Approach 1:
The patent replaces destructive mechanical testing with nondestructive ultrasonic measurement, allowing each part to be tested without damage. This enables 100% inspection while maintaining production efficiency, as parts do not need to be destroyed or disassembled for testing.
Solution Approach 2:
The ultrasonic testing method allows continuous, rapid measurement of connection force without interrupting the production flow. Multiple parts can be tested in sequence without the time-consuming setup and teardown required by traditional methods, maintaining continuous productive action.
3Measurement precision
If connection force is measured by traditional methods, then measurement can be obtained, but testing accuracy is low and cannot satisfy current production demands
Solution Approach 1:
The patent substitutes traditional mechanical measurement methods with ultrasonic wave-based measurement. The ultrasonic technique provides high-precision measurement of connection force by analyzing wave propagation characteristics, achieving accuracy that satisfies modern production demands while improving efficiency.
Solution Approach 2:
The patent changes the measurement parameter from direct mechanical force measurement to ultrasonic signal parameter analysis (amplitude, time of flight, frequency). This parameter transformation enables more precise and efficient measurement of connection force, as ultrasonic parameters can be rapidly captured and analyzed with high precision.
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 device achieves high testing accuracy and efficiency by automating the measurement process, reducing human error, and providing visualization of stress distribution for defect analysis, thus improving the reliability of connection force measurement in interference fit parts.
Implementation Method 1
uses a point focusing water immersion probe to measure stress distribution and calculate connection force by transmitting ultrasonic signals
Data Source
AI summary
An ultrasonic testing device and method for the connection force of interference fit. The motion control module can realize accurate positioning for the interference fit part and accurate control for motion in the circumferential direction and the axial direction; scanning increments of the circumferential direction and the axial direction are set, and the motion control module drives the interference fit part to perform circumferential and axial point scanning until the testing of the whole matching surface is completed. The ultrasonic signal measured by the point focusing water immersion probe is transmitted to a PC through a control loop in the testing process. Then the stress distribution of the matching surface is obtained through the relationship between the ultrasonic signal and contact stress Finally, the size of the connection force is calculated according to the static friction coefficient.