金属板表面电磁超声探伤技术的研究
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摘要
电磁超声(EMAT)因其无需耦合剂,耐高温,易操作等诸多优势,而被广泛研究。目前电磁超声波可以在火车车轮、钢板、铝板、钢管等缺陷检测中应用。在国内外已经成为主流的无损检测方法之一。基于电磁超声原理,进行了电磁表面波的研究。由于表面波具有单模式,能量集中,在试样的表层传播,因此其适合用于金属板材表面的大范围健康状况检测。
课题研究了电磁超声表面波的产生原理以及传播特性,并以此为基础,采用ANSYS软件进行有限元仿真。利用折线形线圈和单磁铁的组合建立电磁超声换能器的3-D有限元模型。为简化有限元求解,将EMAT产生的电磁超声表面波分为电磁场、涡流、洛伦兹力、波动四个部分进行分析,之后对铝板进行了表面波的产生与传播的仿真。以有限元仿真为基础,搭建了由激励、接收和换能器组成的电磁超声表面波金属板探伤检测装置。该检测装置利用FPGA产生正负两路以及频率和周波数可调的脉冲串,并采用多级放大解决电磁超声回波的接收信号比较微弱的问题。利用产生的表面波对金属板中的缺陷进行检测,并进行了声场指向性试验。
ANSYS仿真中,电磁超声换能器的3-D的有限元模型在厚度30mm的铝板中,产生的洛伦兹力使铝板发生质点位移变化,形成表面波。在实际试验中,在长600mm,宽300mm,厚30mm的铝板和钢板上进行试验,经试验验证,电磁超声表面波探伤检测装置可在铝板与钢板中产生表面波,产生的表面波能够对板中的缺陷进行检测。声场指向性试验证明表面波传播具有指向性。回波信号经小波降噪处理后,达到了预期效果,信号得以清晰展示。
Many advantages of electromagnetic acoustic(EMAT), such as no couplant, high temperature resistant and easy operation, make it be widely studied. At present, electromagnetic acoustic has been used in the detection of train wheels, plate, aluminum and steel. Based on the principle of electromagnetic acoustic, electromagnetic surface wave was studied on in this paper. The electromagnetic surface wave is suitable for a wide range of health status detection on the surface of sheet metal because of its single pattern, energy concentration and propagating on the surface of the sample.
This paper studied on the production principle of electromagnetic acoustic surface wave and propagation characteristics, based on which ANSYS software was used to conduct finite element simulations. The polygonal-shape coil and single magnet were combination to establish the 3D finite element model of the electromagnetic acoustic transducer. The electromagnetic acoustic surface wave produced by EMAT was divided into four parts, which were the electromagnetic field, eddy current, the Lorentz force and fluctuations, to make a analysis. And then the simulations of the aluminum plate were conducted to the production and propagation of the electromagnetic acoustic surface wave. The metal plate inspection detection device of the electromagnetic acoustic surface wave, which was consisted of the incentive, receiving and transducer, was put up based on the finite element simulation. The problem, which was the weak receiving single of the electromagnetic acoustic echo, was solved with the multi-stage amplification and the positive and negative two roads, the adjustable frequency and cycle of the pulse train generated by FPGA. The electromagnetic acoustic surface wave was used to detect the defects of the metal plate and the test of the sound field directivity was also conducted.
The Lorentz force generated by 3D finite element model of the electromagnetic acoustic transducer made a displacement change of particle in the 30mm aluminum plate during the ANSYS simulation. The test was conducted on the aluminum plate and steel plate with 600mm long, 300mm width and 300mm thick. The test verified that the metal plate inspection detection device of the electromagnetic acoustic surface wave could generate a surface wave on the aluminum plate and steel plate, which could detect the defects in the plate. The test of the sound field directivity proved that the propagation of the surface wave had directivity. The echo single could reach the expected effect and the single could be displayed clearly by wavelet de-noising processing.
课题研究了电磁超声表面波的产生原理以及传播特性,并以此为基础,采用ANSYS软件进行有限元仿真。利用折线形线圈和单磁铁的组合建立电磁超声换能器的3-D有限元模型。为简化有限元求解,将EMAT产生的电磁超声表面波分为电磁场、涡流、洛伦兹力、波动四个部分进行分析,之后对铝板进行了表面波的产生与传播的仿真。以有限元仿真为基础,搭建了由激励、接收和换能器组成的电磁超声表面波金属板探伤检测装置。该检测装置利用FPGA产生正负两路以及频率和周波数可调的脉冲串,并采用多级放大解决电磁超声回波的接收信号比较微弱的问题。利用产生的表面波对金属板中的缺陷进行检测,并进行了声场指向性试验。
ANSYS仿真中,电磁超声换能器的3-D的有限元模型在厚度30mm的铝板中,产生的洛伦兹力使铝板发生质点位移变化,形成表面波。在实际试验中,在长600mm,宽300mm,厚30mm的铝板和钢板上进行试验,经试验验证,电磁超声表面波探伤检测装置可在铝板与钢板中产生表面波,产生的表面波能够对板中的缺陷进行检测。声场指向性试验证明表面波传播具有指向性。回波信号经小波降噪处理后,达到了预期效果,信号得以清晰展示。
Many advantages of electromagnetic acoustic(EMAT), such as no couplant, high temperature resistant and easy operation, make it be widely studied. At present, electromagnetic acoustic has been used in the detection of train wheels, plate, aluminum and steel. Based on the principle of electromagnetic acoustic, electromagnetic surface wave was studied on in this paper. The electromagnetic surface wave is suitable for a wide range of health status detection on the surface of sheet metal because of its single pattern, energy concentration and propagating on the surface of the sample.
This paper studied on the production principle of electromagnetic acoustic surface wave and propagation characteristics, based on which ANSYS software was used to conduct finite element simulations. The polygonal-shape coil and single magnet were combination to establish the 3D finite element model of the electromagnetic acoustic transducer. The electromagnetic acoustic surface wave produced by EMAT was divided into four parts, which were the electromagnetic field, eddy current, the Lorentz force and fluctuations, to make a analysis. And then the simulations of the aluminum plate were conducted to the production and propagation of the electromagnetic acoustic surface wave. The metal plate inspection detection device of the electromagnetic acoustic surface wave, which was consisted of the incentive, receiving and transducer, was put up based on the finite element simulation. The problem, which was the weak receiving single of the electromagnetic acoustic echo, was solved with the multi-stage amplification and the positive and negative two roads, the adjustable frequency and cycle of the pulse train generated by FPGA. The electromagnetic acoustic surface wave was used to detect the defects of the metal plate and the test of the sound field directivity was also conducted.
The Lorentz force generated by 3D finite element model of the electromagnetic acoustic transducer made a displacement change of particle in the 30mm aluminum plate during the ANSYS simulation. The test was conducted on the aluminum plate and steel plate with 600mm long, 300mm width and 300mm thick. The test verified that the metal plate inspection detection device of the electromagnetic acoustic surface wave could generate a surface wave on the aluminum plate and steel plate, which could detect the defects in the plate. The test of the sound field directivity proved that the propagation of the surface wave had directivity. The echo single could reach the expected effect and the single could be displayed clearly by wavelet de-noising processing.
引文
[1]吴朝晖.超声无损检测的应用与探讨.宁波工程学院学报,2005,17(4):22~24.
[2]徐晨曦.脉冲涡流检测试验系统的研制:(硕士学位论文).上海:上海交通大学,2009.
[3]卢彬.无损检测技术及其进展.焦作大学学报,2004,1(1):73~74.
[4]丁辉.计算超声学.北京:科学出版社,2010.20~32.
[5]刘松平.无损检测新技术——永恒的发展主题.无损检测,2004,26(9):32.
[6]李振才.电磁超声(EMA)技术的发展与应用.无损探伤,2006,30(6):13~14.
[7]高文凭.金属板电磁超声导波机理研究与仿真分析:(硕士学位论文).沈阳:沈阳工业大学2011.
[8]康磊.用于铝板检测的电磁超声导波换能器优化设计技术研究:(博士学位论文).哈尔滨:哈尔滨工业大学,2010.
[9] B.W.Maxfield,A.Kuramoto,J.K.Hulbert.Evaluating EMAT designs for selected applications. Materials Evaluation.1987,(45):1165~1183.
[10]任晓可.电磁超声技术在钢板缺陷检测中的研究:(硕士学位论文).天津:天津大学,2008.
[11] Sawaragi K,et al.Improvement of SH-wave EMAT phased array inspection by new eight segment probes.Nuclear Engineering and design.2000,198(1-2):153~163.
[12]蒯淑君.电磁超声测厚方法与系统的研究:(硕士学位论文).合肥:合肥工业大学,2010.
[13] L.Rayleigh.On waves propagated along the plane surface of an elastic solid.Proc.London Math.Soc.1885,17:4~11.
[14] Thompson R B.Strain dependence of electromagnetic generation of detection of ultrasonic surface waves in ferrous metals.Applied Physice letters.1976,28(9):483~485.
[15] Thompson R B.Model for the electromagnetic generation and detection of Rayleigh and lamb waves.IEEE Transactions on Sonics and Ultrasonics.1973,SU-20(4):340~346.
[16] Ludwig R You Z and Palanisamy R.Numerical simulations of an electromagnetic acoustic transducer-receiver system for NDT applications.1993,29(3):2081~2089.
[17] R.Lerch,M.Kaltenbacher,H.landes,et al.Advanced Computer Modeling of Magnetomechanical Transducers and Their Sound Fields. 2000 IEEE Ultrasonics Symposium.2000:747~758.
[18]任晓可,李建.电磁超声无损检测技术的ANSYS仿真研究.电子测量技术,2008,31(7):27~34.
[19]宫佳鹏,许霁,邱玉,王淑娟.基于电磁超声导波的铝合金板材缺陷自动检测装置.仪表技术与传感器,2011(5),78~81.
[20]王淑娟,康磊,赵再新等.电磁超声换能器的研究进展综述.仪表技术与传感器,2006(5):47~50.
[21]郝宽胜,黄松岭赵伟,王坤.电磁超声换能器线圈阻抗及匹配电容的计算.高技术通讯,2010,8,845-849.
[22]虞福春,郑春开.电动力学.北京:北京大学出版社,2003.109~117.
[23] H.Salzburger,G.Dobmann,H.Mohrbacher.Quality control of laser welds of tailored blanks usingguided waves and EMATs.IEE Proc.-Sci.Meas.Technol.2001,148(4):143~148.
[24]倪光正.工程电磁场原理.北京:高等教育出版社,2002.35~37.
[25]孙雨施.关于永磁的计算模型.电子学报,1982,(5):86~89.
[26] K.Mirkhani,C.Changgares,C.Masterson,et al.Optimal design of EMAT transmittters.NDT&E International.2004,(37):181~193.
[27]师蔚.通过式轨道车辆车轮无损检测装置的研究:(硕士学位论文).上海:同济大学,2005.
[28] Park C I,Cho S H,Kim Y Y.Torsional wave transduction using obliquely-bonded magnetostrictive nickel strips in cylinders.Rotterdam,Netherlands:Institute of Electrial and Electronics Engineers Inc.,2005,713~716.
[29]申建中,张仲宁,张淑仪.电磁超声换能器的频率特性.全国声学学术会议,厦门: 2006:551~552.
[30] SongSong Li, Toshimi Okada, Xiaoming Chen. Electromagnetic acoustic transducer for generation and detection of guided waves. Japanese Journal of Applied Physics, 2006, 45: 4541~4546.
[31]张志刚,阙沛文,雷华明.表面波电磁声换能器及电声学特性的研究.声学技术,2006,25(2):119~123.
[32]朱秀娟.有限元分析网格划分的关键技巧.机械工程与自动化,2009,152(1):186~186.
[33]高炳魁.基于ANSYS直流电测深法的边坡勘探正演:(硕士学位论文).长沙:中南大学,2008.
[34]杨理践.张璐瑶,高松巍,邢燕好.电磁超声表面波产生机理的ANSYS仿真.信息技术与应用学术会议论文,2009(6):186~191.
[35]栾建卫.高质量钢轨超声波探伤装置的研制:(硕士学位论文).昆明:昆明理工大学,2006.
[36]高松巍,李冰,邢燕好.电磁超声在钢管探伤中的应用.沈阳工业大学学报,2009,31(5):582~586.
[37]王娟,郭熙宝.基于DDS的正弦信号发生器的设计.电子技术,2009(5):50~52.
[38] L.Svilainis,G.Motiejunas.Power amplifier for ultrasonic transducer excitation ,Signal processing department, Kaunas University o f Technology,2006(58):30-36.
[39]康磊,王淑娟等.用于电磁超声检测系统的宽带匹配电路的设计.仪表技术与传感器,2007(4):50~53.
[40] Analog device. AD604 Datasheet,2003.
[41]孙颖,李醒飞,张国雄.AD604及其在医用超声系统中的应用.国外电子软器件,2003,2:29~31.
[42]孙颖,李醒飞,张国雄.超声衰减增益补偿电路设计.声学技术,2003,22(4):243~245.
[43] Jafari Shapoorabadi R,Sinclair AN. Improved finite element method for EMAT analysis and design.IEEE Tran Magnetics.2001,37(4);2821~2823.
[44]潘伟才.基于FPGA的电磁超声检测系统的研究:(硕士学位论文).哈尔滨:哈尔滨工业大学,2008.
[45]刘瑾,雷毅.小波分析在超声检测信号处理中的应用.电焊机,2007,40 (7):77~80.
[46]索进章,梁昭峰,董守龙,黄聪明.小波阈值去噪法在超声信号处理中的应用研究.噪声与振动控制,2006,3:35~38.
[47]刘素美,李书光.超声检测信号处理的小波基选取.新疆石油学院学报,2004,16(4):75~78.
[48]刘瑾.基于小波分析的超声波降噪研究:(硕士学位论文).北京:中国石油大学,2010.
[2]徐晨曦.脉冲涡流检测试验系统的研制:(硕士学位论文).上海:上海交通大学,2009.
[3]卢彬.无损检测技术及其进展.焦作大学学报,2004,1(1):73~74.
[4]丁辉.计算超声学.北京:科学出版社,2010.20~32.
[5]刘松平.无损检测新技术——永恒的发展主题.无损检测,2004,26(9):32.
[6]李振才.电磁超声(EMA)技术的发展与应用.无损探伤,2006,30(6):13~14.
[7]高文凭.金属板电磁超声导波机理研究与仿真分析:(硕士学位论文).沈阳:沈阳工业大学2011.
[8]康磊.用于铝板检测的电磁超声导波换能器优化设计技术研究:(博士学位论文).哈尔滨:哈尔滨工业大学,2010.
[9] B.W.Maxfield,A.Kuramoto,J.K.Hulbert.Evaluating EMAT designs for selected applications. Materials Evaluation.1987,(45):1165~1183.
[10]任晓可.电磁超声技术在钢板缺陷检测中的研究:(硕士学位论文).天津:天津大学,2008.
[11] Sawaragi K,et al.Improvement of SH-wave EMAT phased array inspection by new eight segment probes.Nuclear Engineering and design.2000,198(1-2):153~163.
[12]蒯淑君.电磁超声测厚方法与系统的研究:(硕士学位论文).合肥:合肥工业大学,2010.
[13] L.Rayleigh.On waves propagated along the plane surface of an elastic solid.Proc.London Math.Soc.1885,17:4~11.
[14] Thompson R B.Strain dependence of electromagnetic generation of detection of ultrasonic surface waves in ferrous metals.Applied Physice letters.1976,28(9):483~485.
[15] Thompson R B.Model for the electromagnetic generation and detection of Rayleigh and lamb waves.IEEE Transactions on Sonics and Ultrasonics.1973,SU-20(4):340~346.
[16] Ludwig R You Z and Palanisamy R.Numerical simulations of an electromagnetic acoustic transducer-receiver system for NDT applications.1993,29(3):2081~2089.
[17] R.Lerch,M.Kaltenbacher,H.landes,et al.Advanced Computer Modeling of Magnetomechanical Transducers and Their Sound Fields. 2000 IEEE Ultrasonics Symposium.2000:747~758.
[18]任晓可,李建.电磁超声无损检测技术的ANSYS仿真研究.电子测量技术,2008,31(7):27~34.
[19]宫佳鹏,许霁,邱玉,王淑娟.基于电磁超声导波的铝合金板材缺陷自动检测装置.仪表技术与传感器,2011(5),78~81.
[20]王淑娟,康磊,赵再新等.电磁超声换能器的研究进展综述.仪表技术与传感器,2006(5):47~50.
[21]郝宽胜,黄松岭赵伟,王坤.电磁超声换能器线圈阻抗及匹配电容的计算.高技术通讯,2010,8,845-849.
[22]虞福春,郑春开.电动力学.北京:北京大学出版社,2003.109~117.
[23] H.Salzburger,G.Dobmann,H.Mohrbacher.Quality control of laser welds of tailored blanks usingguided waves and EMATs.IEE Proc.-Sci.Meas.Technol.2001,148(4):143~148.
[24]倪光正.工程电磁场原理.北京:高等教育出版社,2002.35~37.
[25]孙雨施.关于永磁的计算模型.电子学报,1982,(5):86~89.
[26] K.Mirkhani,C.Changgares,C.Masterson,et al.Optimal design of EMAT transmittters.NDT&E International.2004,(37):181~193.
[27]师蔚.通过式轨道车辆车轮无损检测装置的研究:(硕士学位论文).上海:同济大学,2005.
[28] Park C I,Cho S H,Kim Y Y.Torsional wave transduction using obliquely-bonded magnetostrictive nickel strips in cylinders.Rotterdam,Netherlands:Institute of Electrial and Electronics Engineers Inc.,2005,713~716.
[29]申建中,张仲宁,张淑仪.电磁超声换能器的频率特性.全国声学学术会议,厦门: 2006:551~552.
[30] SongSong Li, Toshimi Okada, Xiaoming Chen. Electromagnetic acoustic transducer for generation and detection of guided waves. Japanese Journal of Applied Physics, 2006, 45: 4541~4546.
[31]张志刚,阙沛文,雷华明.表面波电磁声换能器及电声学特性的研究.声学技术,2006,25(2):119~123.
[32]朱秀娟.有限元分析网格划分的关键技巧.机械工程与自动化,2009,152(1):186~186.
[33]高炳魁.基于ANSYS直流电测深法的边坡勘探正演:(硕士学位论文).长沙:中南大学,2008.
[34]杨理践.张璐瑶,高松巍,邢燕好.电磁超声表面波产生机理的ANSYS仿真.信息技术与应用学术会议论文,2009(6):186~191.
[35]栾建卫.高质量钢轨超声波探伤装置的研制:(硕士学位论文).昆明:昆明理工大学,2006.
[36]高松巍,李冰,邢燕好.电磁超声在钢管探伤中的应用.沈阳工业大学学报,2009,31(5):582~586.
[37]王娟,郭熙宝.基于DDS的正弦信号发生器的设计.电子技术,2009(5):50~52.
[38] L.Svilainis,G.Motiejunas.Power amplifier for ultrasonic transducer excitation ,Signal processing department, Kaunas University o f Technology,2006(58):30-36.
[39]康磊,王淑娟等.用于电磁超声检测系统的宽带匹配电路的设计.仪表技术与传感器,2007(4):50~53.
[40] Analog device. AD604 Datasheet,2003.
[41]孙颖,李醒飞,张国雄.AD604及其在医用超声系统中的应用.国外电子软器件,2003,2:29~31.
[42]孙颖,李醒飞,张国雄.超声衰减增益补偿电路设计.声学技术,2003,22(4):243~245.
[43] Jafari Shapoorabadi R,Sinclair AN. Improved finite element method for EMAT analysis and design.IEEE Tran Magnetics.2001,37(4);2821~2823.
[44]潘伟才.基于FPGA的电磁超声检测系统的研究:(硕士学位论文).哈尔滨:哈尔滨工业大学,2008.
[45]刘瑾,雷毅.小波分析在超声检测信号处理中的应用.电焊机,2007,40 (7):77~80.
[46]索进章,梁昭峰,董守龙,黄聪明.小波阈值去噪法在超声信号处理中的应用研究.噪声与振动控制,2006,3:35~38.
[47]刘素美,李书光.超声检测信号处理的小波基选取.新疆石油学院学报,2004,16(4):75~78.
[48]刘瑾.基于小波分析的超声波降噪研究:(硕士学位论文).北京:中国石油大学,2010.