CN112595779A - Ultrasonic synchronous strengthening and flaw detection device for crankshaft parts - Google Patents
Ultrasonic synchronous strengthening and flaw detection device for crankshaft parts Download PDFInfo
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- CN112595779A CN112595779A CN202011620728.6A CN202011620728A CN112595779A CN 112595779 A CN112595779 A CN 112595779A CN 202011620728 A CN202011620728 A CN 202011620728A CN 112595779 A CN112595779 A CN 112595779A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
- G01N29/043—Analysing solids in the interior, e.g. by shear waves
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D10/00—Modifying the physical properties by methods other than heat treatment or deformation
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/22—Details, e.g. general constructional or apparatus details
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/02—Indexing codes associated with the analysed material
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Abstract
The invention discloses an ultrasonic synchronous strengthening and flaw detection device for a crankshaft part, which comprises a base, wherein a first support is arranged at the front part of the base, a first slide rail is arranged at the top part of the first support, a first ultrasonic flaw detection device and a second ultrasonic flaw detection device are arranged on the first slide rail, a pair of second supports are arranged at the middle part of the base and are used for supporting a crankshaft, a third support is arranged at the rear part of the base, a second slide rail is arranged on the third support, and a first ultrasonic strengthening device and a second ultrasonic strengthening device are arranged on the second slide rail, wherein waveform diagrams obtained by flaw detection are displayed on a display by the first ultrasonic flaw detection device and the second ultrasonic flaw detection device. The ultrasonic synchronous strengthening and flaw detection device for the crankshaft part has the following advantages: by carrying out ultrasonic synchronous strengthening and flaw detection on the crankshaft parts, parts with huge defects in the casting and forging stage can be screened out at the first time, and resource waste of subsequent processing is avoided.
Description
Technical Field
The invention relates to crankshaft machining equipment, in particular to an ultrasonic synchronous strengthening and flaw detection device for crankshaft parts.
Background
The surface of the crankshaft needs to be continuously rubbed in the working process, wear pits, pitting corrosion and the like easily occur due to poor surface strength, and fatigue failure also occurs. During the production process of the crankshaft, a plurality of air holes or holes are formed in the crankshaft in the casting stage, the mechanical property of the crankshaft is obviously reduced, most of the air holes can be eliminated during forging processing, but a plurality of tiny air holes still remain in the crankshaft. In addition, because of temperature cold and hot changes in metal processing, micro cracks can appear in the crankshaft, and the micro cracks become fracture sources in the service process, so that the service life of the crankshaft is shortened. At present, the fatigue strength of the crankshaft is improved by adopting a rolling mode, but the rolling strengthening process is complex, and the effect is not as good as that of ultrasonic surface strengthening.
The ultrasonic surface strengthening technology mainly utilizes piezoelectric ceramics and a magnetostrictive transducer to effectively convert electric energy into mechanical energy. After amplitude-variable energy collection, huge instant energy is generated in the ultrasonic generating device to impact and collide the surface of the crankshaft, local plastic deformation is formed on the surface of the material, and participated pressure stress is generated on the surface, so that the fatigue resistance of the crankshaft is improved. In addition, the ultrasonic strengthening can change the microstructure on the surface of the crankshaft, refine crystal grains, discharge partial air holes and further improve the compactness of the crankshaft.
Ultrasonic flaw detection is to detect various defects inside metal material by means of the characteristic that the metal material penetrates into the body of the metal material and is reflected from the edge of the interface when entering another section from one section. When ultrasonic waves are transmitted into metal from the probe and encounter defects such as air holes, reflected waves similar to the interface at the bottom of the metal can appear, pulse waveforms in different shapes are finally formed on the fluorescent screen, and workers judge the positions and sizes of the defects in the crankshaft according to the waveforms on the fluorescent screen.
But the effect of ultrasonic strengthening for the crankshaft needs to adjust the process parameters such as ultrasonic energy, scanning speed, scanning path and the like according to the type and mechanical property of the material. On one hand, the ultrasonic strengthening forms a plastic deformation layer and a residual compressive stress layer with certain thickness on the surface of the crankshaft, and the thickness of the layers needs to be determined through actual analysis. On the other hand, the discharge condition of the internal air holes and the micro damage condition caused by the uncoordinated deformation in the strengthening process need to be observed and analyzed in time by ultrasonic strengthening.
The above prior art solutions still have the following drawbacks: the crankshaft can not be subjected to nondestructive flaw detection while ultrasonic strengthening, the tiny defects generated in the strengthening stage can not be found in time, in addition, the influence degree of the ultrasonic strengthening on internal air holes, tiny cracks and density can not be fed back in time, and specific ultrasonic optimized processing parameters can not be given through ultrasonic flaw detection.
Disclosure of Invention
The invention mainly solves the technical problems in the prior art, and provides an ultrasonic synchronous strengthening and flaw detection device for crankshaft parts.
The technical problem of the invention is mainly solved by the following technical scheme:
an ultrasonic synchronous strengthening and flaw detection device for crankshaft parts comprises a base and is characterized in that,
the front part of the base is provided with a first bracket, the top of the first bracket is provided with a first slide rail, the first slide rail is provided with a first ultrasonic flaw detection device and a second ultrasonic flaw detection device,
a pair of second brackets are arranged in the middle of the base and used for supporting a crankshaft,
the rear part of the base is provided with a third bracket, the third bracket is provided with a second slide rail, the second slide rail is provided with a first ultrasonic strengthening device and a second ultrasonic strengthening device,
wherein, the first ultrasonic flaw detection device and the second ultrasonic flaw detection device display the waveform images obtained by flaw detection on a display.
The ultrasonic synchronous strengthening and flaw detection device for the crankshaft part has the following advantages: by carrying out ultrasonic synchronous strengthening and flaw detection on the crankshaft parts, parts with huge defects in the casting and forging stage can be screened out at the first time, and resource waste of subsequent processing is avoided. The method has the advantages that ultrasonic flaw detection is carried out while ultrasonic strengthening is adopted, the influence of the ultrasonic strengthening on internal defects of the crankshaft can be monitored in real time, curves on a display are analyzed, the occurrence time of the internal defects is judged, the conditions are fed back to a casting and forging responsible person or an ultrasonic strengthening responsible person in time, and the machining process and the repairing process of the crankshaft parts are optimized.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic structural diagram of an ultrasonic synchronous strengthening and flaw detection device for crankshaft parts according to the invention;
FIG. 2 is a schematic diagram of the simultaneous ultrasonic reinforcement and ultrasonic flaw detection.
Detailed Description
The preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings so that the advantages and features of the present invention can be more easily understood by those skilled in the art, and the scope of the present invention will be more clearly and clearly defined.
As shown in fig. 1 and fig. 2, the ultrasonic synchronous strengthening and flaw detection device for crankshaft parts comprises a base 1, a first support 3 is arranged at the front part of the base 1, a first slide rail 4 is arranged at the top part of the first support 3, a first ultrasonic flaw detection device 2 and a second ultrasonic flaw detection device 5 are arranged on the first slide rail 4,
a pair of second brackets 6 are arranged in the middle of the base 1, the second brackets 6 are used for supporting a crankshaft 7,
the rear part of the base 1 is provided with a third support 10, the third support 10 is provided with a second slide rail 11, and the second slide rail 11 is provided with a first ultrasonic strengthening device 8 and a second ultrasonic strengthening device 9.
Wherein the first ultrasonic testing device 2 and the second ultrasonic testing device 5 display the waveform images obtained by testing on a display 12.
The working mode of the ultrasonic synchronous strengthening and flaw detection device for the crankshaft part is as follows.
The embodiment adopts a sample of a motorcycle crankshaft part, the sample is made of 45 steel, and the method comprises the following steps:
step S1, grinding the machined part of the crankshaft 7 by using sand paper, cleaning, drying, placing on the second bracket 6, connecting the crankshaft 7 with the motor through a clamp, stabilizing the other end of the crankshaft, avoiding the consistency of the precision in the rotating process, ensuring the rotating uniformity of the crankshaft, and setting the rotating speed of the motor to be 1 r/min;
step S2, setting a motion controller connected with a PLC, and controlling the first ultrasonic flaw detection device 2 and the second ultrasonic flaw detection device 5 to reciprocate on the first slide rail 4, wherein the reciprocating distance is equal to the crank thickness of the crankshaft;
step S3, starting the first ultrasonic flaw detection device 2 and the second ultrasonic flaw detection device 5, displaying the waveform images obtained by flaw detection on the display 12, reflecting the ultrasonic waves on the surface and the bottom of the metal, transmitting the emitted waveforms to the first ultrasonic flaw detection device 2 and the second ultrasonic flaw detection device 5 through the surface of the crankshaft 7, and displaying the waveforms through the display 12;
step S4, setting a motion controller connected with a PLC, controlling the first ultrasonic strengthening device 8 and the second ultrasonic strengthening device 9 to act on the second slide rail 11, wherein the action is divided into two steps:
the first step is to keep the crankshaft 7 stationary for 1 minute, the crankshaft rotates at a constant speed for 1 circle under the drive of the motor, the first ultrasonic strengthening device 8 and the second ultrasonic strengthening device 9 are respectively strengthened uniformly in the horizontal direction of the crank,
the second step is to move at a constant speed along the horizontal direction under the action of the motion controller, the moving speed is controlled to be 0.5mm/min, at the moment, the crankshaft 7 rotates along the axial direction, the first ultrasonic strengthening device 8 and the second ultrasonic strengthening device 9 move along the horizontal direction, and finally, the ultrasonic strengthening track is in a spiral line shape.
Ultrasonic strengthening, while increasing crankshaft fatigue strength, may result in inconsistent internal deformation of the crankshaft and excessive stress and even microscopic defects, which are reflected in the display 12.
According to the ultrasonic flaw detection result, whether the current crankshaft can meet the use requirement of the part is judged, and then whether the parameters of ultrasonic strengthening need to be adjusted or not is analyzed according to various performance requirements of the part on the material, so that the ultrasonic strengthening depth and the surface residual compressive stress are increased or reduced. The parameters for ultrasonic strengthening adjustment mainly include maximum power, strengthening track and strengthening times. The ultrasonic strengthening power directly influences the influence of single strengthening on the surface performance of the crankshaft; the strengthening track can affect the residual stress distribution of the final crankshaft part; the reinforcement times are to further enhance the ultrasonic reinforcement effect under the condition that the ultrasonic reinforcement power is fixed.
If there are no internal defects, the waveform displayed on the display 12 is similar to the curve 13. The waveform of the curve 13 mainly has two peaks, the first peak is a signal received by a signal receiver after the ultrasonic wave is reflected by the crankshaft at one side close to the ultrasonic flaw detection device, namely a surface signal; the second peak is the signal received by the signal receiver after the ultrasonic wave is reflected by the crankshaft at the side away from the ultrasonic testing device, i.e. the bottom signal. If the defects such as cracks and air holes do not exist in the crankshaft and the compactness is good, signal fluctuation does not exist.
Since the crankshaft is a forged part, the detected intermediate peaks mainly correspond to the micro cracks when the crankshaft is ultrasonically inspected.
If a minute crack defect exists at a portion of the crankshaft 7 near the inspection surface during the forging stage or the ultrasonic surface strengthening stage, the waveform shown on the display 12 is similar to that of the curve 14. The waveform of curve 14 has three main peaks, the first and third peaks representing the signals reflected by the ultrasonic waves at the surface and the bottom, respectively; the second peak indicates the presence of a crack defect within the crankshaft, and the proximity of the first peak indicates the location of the crack on the side of the surface that was ultrasonically inspected.
If a minute crack defect exists at a position of the crankshaft 7 far from the inspection surface during the forging stage or the ultrasonic surface strengthening stage, the waveform shown on the display 12 is similar to that of the curve 15. The waveform of curve 15 also has three peaks, the first and third peaks representing the signals reflected by the ultrasonic waves at the surface and at the bottom, respectively; the second peak indicates the presence of a crack defect within the crankshaft, and the proximity of the third peak indicates the side of the crack location away from the ultrasonically inspected surface.
The second peaks of the curves 14 and 15 indicate that the crack is located close to the ultrasonic detection position and away from the ultrasonic detection position, respectively, so both the curves 14 and 15 are collectively regarded as the crack is located close to the surface of the crankshaft.
If a minute crack defect is caused in the core portion of the crankshaft 7 at the forging stage or the ultrasonic surface hardening stage, the waveform shown on the display 12 is similar to that of the curve 16. The waveform of curve 16 also has three peaks, the first and third peaks representing the signals reflected by the ultrasound waves at the surface and at the bottom, respectively; the second peak indicates the presence of crack defects inside the crankshaft.
If the peaks in curve 14, curve 15 and curve 16 are close, it is indicated that the texture is loose here and there are more micro-cracks.
Judging the position and the length of the micro crack according to the curve 14 or the curve 15, giving a repairing scheme, and giving the required impact times of the laser impact power meter if the laser impact strengthening repairing is adopted; if cutting machining and laser cladding remanufacturing and repairing are adopted, the required cutting depth is given, and the secondary result is fed back to a front-end operator.
Judging the distance and the length between the micro crack and the crankshaft core according to the curve 16, giving a reasonable repair scheme, removing the crack through re-forging, and calibrating and recycling if the crack is too large and cannot be repaired.
The results show that parts with huge defects in the casting and forging stage can be screened out at the first time by carrying out ultrasonic synchronous strengthening and flaw detection on the crankshaft parts, so that resource waste of subsequent processing is avoided; the method has the advantages that ultrasonic flaw detection is carried out while ultrasonic strengthening is adopted, the influence of the ultrasonic strengthening on internal defects of the crankshaft can be monitored in real time, curves on a display are analyzed, the occurrence time of the internal defects is judged, the conditions are fed back to a casting and forging responsible person or an ultrasonic strengthening responsible person in time, and the machining process and the repairing process of the crankshaft parts are optimized.
Without being limited thereto, any changes or substitutions that are not thought of through the inventive work should be covered within the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope defined by the claims.
Claims (1)
1. An ultrasonic synchronous strengthening and flaw detection device for crankshaft parts comprises a base (1) and is characterized in that,
a first bracket (3) is arranged at the front part of the base (1), a first slide rail (4) is arranged at the top part of the first bracket (3), a first ultrasonic flaw detection device (2) and a second ultrasonic flaw detection device (5) are arranged on the first slide rail (4),
a pair of second brackets (6) are arranged in the middle of the base (1), the second brackets (6) are used for supporting a crankshaft (7),
a third bracket (10) is arranged at the rear part of the base (1), a second sliding rail (11) is arranged on the third bracket (10), a first ultrasonic strengthening device (8) and a second ultrasonic strengthening device (9) are arranged on the second sliding rail (11),
wherein, the first ultrasonic flaw detection device (2) and the second ultrasonic flaw detection device (5) display the waveform diagram obtained by flaw detection on a display (12).
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| Application Number | Priority Date | Filing Date | Title |
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| CN202011620728.6A CN112595779A (en) | 2020-12-31 | 2020-12-31 | Ultrasonic synchronous strengthening and flaw detection device for crankshaft parts |
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| CN202011620728.6A CN112595779A (en) | 2020-12-31 | 2020-12-31 | Ultrasonic synchronous strengthening and flaw detection device for crankshaft parts |
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| CN112595779A true CN112595779A (en) | 2021-04-02 |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114152671A (en) * | 2021-12-03 | 2022-03-08 | 南通联翔机械有限公司 | Quality detection equipment with flaw detection function for machining cast crankshaft |
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- 2020-12-31 CN CN202011620728.6A patent/CN112595779A/en active Pending
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114152671A (en) * | 2021-12-03 | 2022-03-08 | 南通联翔机械有限公司 | Quality detection equipment with flaw detection function for machining cast crankshaft |
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