焊接残余应力超声波检测装置的研制
摘要
科技的发展对焊接构件的残余应力的无损在役检测提出了越来越高的要求,由此推动了应力检测技术的飞速发展。小孔法、切槽法、X射线法、磁噪声法、光弹性法等一大批残余应力测量方法被研究出来并运用于工程实际中。相较于其他方法,超声波应力测量法具有检测速度快、准确性高、操作方便、环保无污染等优点,因此被公认为是最有前途的应力无损检测手段之一。
本文介绍了超声波的有关特性和临界折射纵波(LCR波)的产生机理,对声弹性理论进行了研究,经过对应力——声速相关公式的简化推导得到了工程实践中运用的超声波测量焊接残余应力的计算公式,同时对公式中的声弹性系数作了标定。
在此基础上,本文设计了超声波应力测量系统的硬件电路和软件程序,详细介绍了整个系统的工作流程和总体结构。对电路中的超声波激发模块、回波预处理模块、计时测量模块等的原理和参数作了明确说明,并对其所能实现的功能进行了测试。同时还详细介绍了高精度时间数字芯片——TDC-GP1的内部结构、测量原理、工作模式等相关信息。
本文利用设计出的焊接残余应力检测系统分别对LCR波在有/无应力的铝合金试件中的传播时间进行了实验测量,通过推导出的公式计算出了铝合金试件的焊接残余应力并得出了其分布趋势。
The development of science and technology puts forward higher and higher requirements on residual stress of welding components lossless in service examination, thus stress detection technology has made rapid development. A large number of methods in measuring stress are finding out and used in engineering practice such as hole method, cutting method, X-ray method, Backhaus law, photoelasticity and so on.
Compared with other methods, the ultrasonic wave law of testing the stress has a lot of advantages, such as rapid detection, high accuracy, easy operation, no pollution and so on. So it is considered the most promising means of non-destructive testing stress.
This paper introduces the characteristics of ultrasonic and the critical refraction wave (LCR wave) generating mechanism, studies the acoustic elasticity theory, gets the calculation formula of ultrasonic testing welded residual stress by simplifying and deriving stress-sound velocity related formula, and demarcates the acoustic elasticity coefficient of the formula at the same time.
On this basis, the paper designs hardware circuit and software routine of ultrasonic stress measurement system, and introduces work flow and gross structure of the intire system in detail. It explains explicitly principle and parameters of the ultrasonic wave stimulation module, the echo pretreatment module, the time survey module and so on, and tests their function. It also introduces the internal structure, measuring principle, working pattern and so on of high accuracy time figure chip--TDC-GP1 in detail.
This paper designed the welding residual stress detection system, tested respectively the propagation time of LCR waves traveled in aluminum alloy specimens with/without the stress , calculated the welding residual stress of aluminum alloy specimens by the formulas, and got the distribution trends of the the welding residual stress.
本文介绍了超声波的有关特性和临界折射纵波(LCR波)的产生机理,对声弹性理论进行了研究,经过对应力——声速相关公式的简化推导得到了工程实践中运用的超声波测量焊接残余应力的计算公式,同时对公式中的声弹性系数作了标定。
在此基础上,本文设计了超声波应力测量系统的硬件电路和软件程序,详细介绍了整个系统的工作流程和总体结构。对电路中的超声波激发模块、回波预处理模块、计时测量模块等的原理和参数作了明确说明,并对其所能实现的功能进行了测试。同时还详细介绍了高精度时间数字芯片——TDC-GP1的内部结构、测量原理、工作模式等相关信息。
本文利用设计出的焊接残余应力检测系统分别对LCR波在有/无应力的铝合金试件中的传播时间进行了实验测量,通过推导出的公式计算出了铝合金试件的焊接残余应力并得出了其分布趋势。
The development of science and technology puts forward higher and higher requirements on residual stress of welding components lossless in service examination, thus stress detection technology has made rapid development. A large number of methods in measuring stress are finding out and used in engineering practice such as hole method, cutting method, X-ray method, Backhaus law, photoelasticity and so on.
Compared with other methods, the ultrasonic wave law of testing the stress has a lot of advantages, such as rapid detection, high accuracy, easy operation, no pollution and so on. So it is considered the most promising means of non-destructive testing stress.
This paper introduces the characteristics of ultrasonic and the critical refraction wave (LCR wave) generating mechanism, studies the acoustic elasticity theory, gets the calculation formula of ultrasonic testing welded residual stress by simplifying and deriving stress-sound velocity related formula, and demarcates the acoustic elasticity coefficient of the formula at the same time.
On this basis, the paper designs hardware circuit and software routine of ultrasonic stress measurement system, and introduces work flow and gross structure of the intire system in detail. It explains explicitly principle and parameters of the ultrasonic wave stimulation module, the echo pretreatment module, the time survey module and so on, and tests their function. It also introduces the internal structure, measuring principle, working pattern and so on of high accuracy time figure chip--TDC-GP1 in detail.
This paper designed the welding residual stress detection system, tested respectively the propagation time of LCR waves traveled in aluminum alloy specimens with/without the stress , calculated the welding residual stress of aluminum alloy specimens by the formulas, and got the distribution trends of the the welding residual stress.
引文
1付学义,刘莉.残余应力的危害及对策.包钢科技. 2004,32(6):7~10
2 Kandil F A, Lord J D, Fry A T and Grant P V. A Re-view of Residual Stress Measurement Methods-AGuide to Technique Selection. NPL Report MATC(A)04, 2001,v2.
3易大斌.钢轨应力及其无损检测[J].中国铁路. 1991,(6):10~14.
4米谷茂[日].残余应力的产生和对策(朱荆璞,邵会孟,译).北京:机械工业出版社. 1983(3):75~103
5周祖华. UT信号频谱分析技术基础研究.大连理工大学. 2002
6 J杰拉德[英].超声检测新技术.北京:科学技术出版社. 1991,(1) :41~53
7罗健豪.无损残余应力测量及其新技术.力学与实践. 2003,(4) :33~71
8杨帆,费维栋. X射线衍射技术在薄膜残余应力测量中的应用.功能材料. 2007,38(11):1745~1749
9孔德军,张永康.基于XRD的薄膜界面结合强度试验研究.中国表面工程. 2007,20(1):38~41
10朱宏喜,毛卫民.金刚石薄膜残余应力的X射线透射测量法.物理测试. 2005,23(6):21~24
11蒋艳平,肖刘. X射线衍射法测Zn电镀层中的残余应力.湘潭大学自然科学学报. 2001,23(4):42~45
12吴廷斌. NiTi形状记忆合金薄膜的残余应力.上海交通大学学报. 2001,35(3):436~439
13刘明珠,杨从晶,于助,等.巴克豪森噪声在应力及疲劳损伤检测上的应用.哈尔滨理工大学学报. 2001,6(1):73~76
14冉启芳,吕克茂.残余应力测定的基本知识——第三讲:磁性法和超声法测残余应力的基本原理和各种方法比较.理化检验-物理. 2007,43(6):317~321
15 Ultrasonic Stress Measurement with the LCR Technique. http://www.brayengr.com/
16 Valerio DEL FABBRO,等.采用超声波检测新车轮应力.国外机车车辆工艺. 1996,26(1):42~57
17 D.Vangi. Stress evaluation by pulse-echo ultrasonic longitudinal wave. ExperimentalMechanics, 2001,41(3):277~281
18 M.Sgalla, D.Vangi. A device for measuring the velocity of ultrasonic waves:Anapplication tostress analysis. Experimental Mechanics. 2004,44(1):85~90
19 D.Vangi, A.Virga. A practical application of ultrasonic thermal stress monitoring incontinuous welded rails. Experimental Mechanics. 2007,47:617~623
20 Minicuci D.J,等(巴西).用超声波探伤评估车轮应力.国外铁道车辆. 2007,44(6):40~46
21贺铃凤.利用激光超声测量H型钢梁的残余应力.华南理工大学学报. 2001,29(7):20~23
22李勇攀.临界折射纵波(LCR波)传播机理的研究.声学技术. 2004,23(3):141~145
23刘蕊.利用LCR波的单通道耦合检测钢轨应力.计量技术. 2004,47(9):32~34
24刘蕊.利用临界折射纵波检测钢轨应力.声学技术. 2004,23(4):246~249
25 Zhangwei Ling, Hongjian Zhang, Hongliang Zhou. Nondestructive Pressure Measurement inVessels Using Rayleigh Waves and LCR Waves. IEEE International Instrumentation andMeasurement Technology Conference, Victoria, Vancouver Island, Canada. May 12,2008
26魏智,徐蔚,曲云霞,付建华.表面波声弹性应力检测基础.河北工业大学学报. 2002,31(1):10~14
27周晓军,江月娟,魏智,徐志龙.航空透明件表面应力声弹检测方法的实验研究.仪器仪表学报. 2000,21(5):497~500
28 D.E.Bray, Wei Tang. Subsurface stress evaluation in steel plates and bars usingthe LCR ultrasonic wave. Nuclear Engineering and Design. 2001,207(2):231~240
29 D.E.Bray. Application of the LCR ultrasonic technique for evaluation ofpost-weld heat treatment in steel plates. NDT&International. 1995,28(4):235~242
30 Yabdallahoui, H walaszek, C Peyrac, H P Lieurade, M Cherfaoui. The use ofultrasonic in the optimization of welding processes. Welding international. 2001,15(4):1~12
31 J.西拉德.超声检测新技术.北京:科学出版社. 1991,65~70
32 Hughes D.S, Kelley J.L. Second-order Elastic Deformation of Solids. Phys. Rev,1951:1145~1149
33 Tatsuo Tokuoka, Yukio Iwashimizu. Acoustical birefringenceof ultrasonic waves in deformed isotropic elastic materials. In J.Solids Structures. 1968(4):383~389
34 Adam Bartosiewicz.Experiences in Application of Ultrasonic StressMeasurements for Railway Industry.国外铁道车辆. 1999,36(6):31~36
35 D.S.Hughes. Ultrasonic velocity in an elastic solid. Journal of Applied Physics. 1950,21(3):294~301
36 D.I.Crecraft. The measurement of applied and residual stresses in metals usingultrasonic waves. Journal of Sound Vibration. 1967,5(1):173~192
37 G.C.Johnson. Acoustoelastic theory for elastic-plastic materials. Acoustic.Soc.Am. 1981,70(2):591~595
38 S.K.Datta, A.H.Shah and W.Karunasena. Edge and Layering Effects In aMultilayered Composite Plate. Computers&Structures. 1990,37(2):151~162
39 Y.Iwashimizu, K.Kubomura. Stress-induced rotation of polarization directions ofelastic waves in slightly anisotropic material. In J Solids Structures. 1973,(9):99~114
40 H.walaszek, H-P.Lieurade, C.Peyrac, J.Hoblos, J.Rivenez. Potentialities of ultrasonic for evaluation residual stresses:influence of microstructure. Journal of Pressure Vessel Technology. 2002,124:349~353
41王彦龙.残余应力的超声波检测研究.西安科技大学硕士论文. 2005:27~28
42张军.基于TDC的LCR波切向应力测量信号处理方法的研究.电子科技大学硕士论文. 2006:10~11
43 Lu H, Liu X S, Yang J G,et al. Ultrasonic stress evaluation on welded plateswithLcrwave. Science&Technology of Welding and Joining. 2008,13(1):70~75
44李勇攀,王寅观,陈振宇,等.临界折射纵波(LcR波)传播机理的研究.声学技术. 2004,23(3):141~145
2 Kandil F A, Lord J D, Fry A T and Grant P V. A Re-view of Residual Stress Measurement Methods-AGuide to Technique Selection. NPL Report MATC(A)04, 2001,v2.
3易大斌.钢轨应力及其无损检测[J].中国铁路. 1991,(6):10~14.
4米谷茂[日].残余应力的产生和对策(朱荆璞,邵会孟,译).北京:机械工业出版社. 1983(3):75~103
5周祖华. UT信号频谱分析技术基础研究.大连理工大学. 2002
6 J杰拉德[英].超声检测新技术.北京:科学技术出版社. 1991,(1) :41~53
7罗健豪.无损残余应力测量及其新技术.力学与实践. 2003,(4) :33~71
8杨帆,费维栋. X射线衍射技术在薄膜残余应力测量中的应用.功能材料. 2007,38(11):1745~1749
9孔德军,张永康.基于XRD的薄膜界面结合强度试验研究.中国表面工程. 2007,20(1):38~41
10朱宏喜,毛卫民.金刚石薄膜残余应力的X射线透射测量法.物理测试. 2005,23(6):21~24
11蒋艳平,肖刘. X射线衍射法测Zn电镀层中的残余应力.湘潭大学自然科学学报. 2001,23(4):42~45
12吴廷斌. NiTi形状记忆合金薄膜的残余应力.上海交通大学学报. 2001,35(3):436~439
13刘明珠,杨从晶,于助,等.巴克豪森噪声在应力及疲劳损伤检测上的应用.哈尔滨理工大学学报. 2001,6(1):73~76
14冉启芳,吕克茂.残余应力测定的基本知识——第三讲:磁性法和超声法测残余应力的基本原理和各种方法比较.理化检验-物理. 2007,43(6):317~321
15 Ultrasonic Stress Measurement with the LCR Technique. http://www.brayengr.com/
16 Valerio DEL FABBRO,等.采用超声波检测新车轮应力.国外机车车辆工艺. 1996,26(1):42~57
17 D.Vangi. Stress evaluation by pulse-echo ultrasonic longitudinal wave. ExperimentalMechanics, 2001,41(3):277~281
18 M.Sgalla, D.Vangi. A device for measuring the velocity of ultrasonic waves:Anapplication tostress analysis. Experimental Mechanics. 2004,44(1):85~90
19 D.Vangi, A.Virga. A practical application of ultrasonic thermal stress monitoring incontinuous welded rails. Experimental Mechanics. 2007,47:617~623
20 Minicuci D.J,等(巴西).用超声波探伤评估车轮应力.国外铁道车辆. 2007,44(6):40~46
21贺铃凤.利用激光超声测量H型钢梁的残余应力.华南理工大学学报. 2001,29(7):20~23
22李勇攀.临界折射纵波(LCR波)传播机理的研究.声学技术. 2004,23(3):141~145
23刘蕊.利用LCR波的单通道耦合检测钢轨应力.计量技术. 2004,47(9):32~34
24刘蕊.利用临界折射纵波检测钢轨应力.声学技术. 2004,23(4):246~249
25 Zhangwei Ling, Hongjian Zhang, Hongliang Zhou. Nondestructive Pressure Measurement inVessels Using Rayleigh Waves and LCR Waves. IEEE International Instrumentation andMeasurement Technology Conference, Victoria, Vancouver Island, Canada. May 12,2008
26魏智,徐蔚,曲云霞,付建华.表面波声弹性应力检测基础.河北工业大学学报. 2002,31(1):10~14
27周晓军,江月娟,魏智,徐志龙.航空透明件表面应力声弹检测方法的实验研究.仪器仪表学报. 2000,21(5):497~500
28 D.E.Bray, Wei Tang. Subsurface stress evaluation in steel plates and bars usingthe LCR ultrasonic wave. Nuclear Engineering and Design. 2001,207(2):231~240
29 D.E.Bray. Application of the LCR ultrasonic technique for evaluation ofpost-weld heat treatment in steel plates. NDT&International. 1995,28(4):235~242
30 Yabdallahoui, H walaszek, C Peyrac, H P Lieurade, M Cherfaoui. The use ofultrasonic in the optimization of welding processes. Welding international. 2001,15(4):1~12
31 J.西拉德.超声检测新技术.北京:科学出版社. 1991,65~70
32 Hughes D.S, Kelley J.L. Second-order Elastic Deformation of Solids. Phys. Rev,1951:1145~1149
33 Tatsuo Tokuoka, Yukio Iwashimizu. Acoustical birefringenceof ultrasonic waves in deformed isotropic elastic materials. In J.Solids Structures. 1968(4):383~389
34 Adam Bartosiewicz.Experiences in Application of Ultrasonic StressMeasurements for Railway Industry.国外铁道车辆. 1999,36(6):31~36
35 D.S.Hughes. Ultrasonic velocity in an elastic solid. Journal of Applied Physics. 1950,21(3):294~301
36 D.I.Crecraft. The measurement of applied and residual stresses in metals usingultrasonic waves. Journal of Sound Vibration. 1967,5(1):173~192
37 G.C.Johnson. Acoustoelastic theory for elastic-plastic materials. Acoustic.Soc.Am. 1981,70(2):591~595
38 S.K.Datta, A.H.Shah and W.Karunasena. Edge and Layering Effects In aMultilayered Composite Plate. Computers&Structures. 1990,37(2):151~162
39 Y.Iwashimizu, K.Kubomura. Stress-induced rotation of polarization directions ofelastic waves in slightly anisotropic material. In J Solids Structures. 1973,(9):99~114
40 H.walaszek, H-P.Lieurade, C.Peyrac, J.Hoblos, J.Rivenez. Potentialities of ultrasonic for evaluation residual stresses:influence of microstructure. Journal of Pressure Vessel Technology. 2002,124:349~353
41王彦龙.残余应力的超声波检测研究.西安科技大学硕士论文. 2005:27~28
42张军.基于TDC的LCR波切向应力测量信号处理方法的研究.电子科技大学硕士论文. 2006:10~11
43 Lu H, Liu X S, Yang J G,et al. Ultrasonic stress evaluation on welded plateswithLcrwave. Science&Technology of Welding and Joining. 2008,13(1):70~75
44李勇攀,王寅观,陈振宇,等.临界折射纵波(LcR波)传播机理的研究.声学技术. 2004,23(3):141~145