CN114137081B - High-sensitivity small-blind-area ultrasonic detection method for bearing ring - Google Patents
High-sensitivity small-blind-area ultrasonic detection method for bearing ring Download PDFInfo
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- 238000001514 detection method Methods 0.000 title claims abstract description 91
- 239000000523 sample Substances 0.000 claims abstract description 52
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 27
- 238000007654 immersion Methods 0.000 claims abstract description 25
- 238000012545 processing Methods 0.000 claims description 16
- 238000004519 manufacturing process Methods 0.000 claims description 12
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Abstract
A high-sensitivity small-blind-area ultrasonic detection method for a bearing ring relates to a detection method for the bearing ring. The method solves the problems of low sensitivity and large blind area in the detection of the micro defects of the bearing ring by the existing water immersion ultrasonic detection method. The method comprises the following steps: 1. preparing a flat bottom hole comparison sample and a raceway flat bottom Kong Shiyang; 2. device sensitivity adjustment; 3. the raceway flat bottom Kong Shiyang is placed in a three-jaw chuck of a water immersion ultrasonic device for locking and centering, the whole outer diameter surface of the raceway flat bottom Kong Shiyang is detected by adopting a longitudinal wave vertical incidence outer diameter surface mode, and a probe focus is beaten on the outer diameter surface of a raceway flat bottom hole sample to obtain detection data. The invention detects the blind area of the incidence surface of the ferrule by 1.5mm, the blind area of the reflecting surface by 0.8mm, ensures the total coverage of internal detection, reduces the surface blind area of ultrasonic detection and improves the defect control range. The invention can accurately detect and locate the micro defects and ensure the detection quality of water immersion ultrasonic. The invention is suitable for the high-sensitivity small blind area ultrasonic detection of the bearing ring.
Description
Technical Field
The invention relates to a detection method of a bearing ring.
Background
Aviation spindle bearings are important transmission components of an aeroengine, and the working reliability of the aviation spindle bearings has an irreplaceable influence on the safety of aviation equipment. The data show that the failure rate of the aviation bearing occupies a large proportion in various major mechanical accidents of the aviation machinery. Therefore, aiming at safety detection of the aviation bearing, the fault rate of aviation equipment is guaranteed, and the aviation accident reduction has very important practical significance. The ferrule is an important component of the bearing, and the aviation bearing brings higher requirements on the aspects of reliability, quality, thrust-weight ratio, working condition, service life and the like along with the development and batch production of three-generation and four-generation machine products, so that the defect control on bearing materials is more and more strict. At present, a method which is relatively suitable for detecting internal defects such as forging folds, holes and the like of aviation bearing forgings is a water immersion ultrasonic method.
The water immersion ultrasonic detection is mainly based on the propagation characteristic of ultrasonic waves in a workpiece, and is one of the detection methods which are widely applied in the current methods for detecting internal micro defects. The water immersion ultrasonic detection technology in the ultrasonic detection method is a more accurate detection method, and an automatic detection system is utilized, and the curved surface tracking scanning, automatic data acquisition and recording, defect positioning and the like can be realized by combining an automatic scanning device. The technical principle is that the wave physical characteristics of the ultrasonic wave propagating in the solid and the liquid, such as the reflection, refraction and wave mode conversion of the ultrasonic wave at the interface when the two medium impedances are different, and the energy of the ultrasonic wave propagating in the solid and the liquid is attenuated. And through signal receiving and analysis, the equivalent size, position and other information of the defect are realized. The quality requirements of the aviation spindle bearing are continuously improved, and a plurality of problems are presented to the water immersion ultrasonic detection technology, such as accurate measurement and positioning of micro defects, high-sensitivity small-blind-area point focusing ultrasonic detection technology and the like.
The blind area on the surface of the detection ferrule is larger, and the total machining allowance of most bearing ferrules is smaller on one side. In order to ensure the whole coverage of the internal detection, the size of an incidence blind area is required to be reduced and the defect control range is required to be improved only by increasing the machining allowance of a forging piece or increasing the reverse incidence detection (which is not easy to realize for a smaller ferrule). The smaller ferrule defects place higher demands on how to define the effects of the different depth defects, determine the ultrasound acceptance level, and control the positioning accuracy of the test.
Disclosure of Invention
The invention aims to solve the problems of low sensitivity and large blind area in the existing water immersion ultrasonic detection method for detecting the micro defects of a bearing ring, and provides a high-sensitivity small blind area ultrasonic detection method for the bearing ring.
The bearing ring high-sensitivity small-blind-area ultrasonic detection method is realized by the following steps:
1. sample preparation:
flat bottom hole comparative sample: the manufacturing material of the flat bottom hole comparison sample is that 8Cr4Mo4V is consistent with the ferrule to be detected, the processing state and the size are the same, and the processing size is as follows: 6 apertures are phi 0.4mm, the diameters are 50.8mm, the burial depths are 1.6mm, 3.2mm, 6.4mm, 12.7mm, 25.4mm and 38.1mm respectively, and the thicknesses are 8.0mm, 9.6mm, 12.8mm, 19.1mm, 31.8mm and 44.5mm respectively;
raceway flat bottom Kong Shiyang: taking rings to be detected, and manufacturing flat bottom holes with different burial depths and near surfaces, wherein the flat bottom holes have the aperture phi of 0.4mm, the hole depths of 0.4mm, 0.8mm, 1.6mm, 3.2mm, 5mm and 6.4mm respectively, and the hole intervals are 5mm in total, and are respectively positioned at the center position of the circular arc bottom of a channel of the rings to be detected and the distance between the center of the circular arc bottom of the channel and the edge of a roller path by 1/2;
2. device sensitivity adjustment:
the flat bottom hole comparison samples are sequentially arranged from thin to thick according to the thickness sequence, the reflection wave height of the flat bottom holes with the embedded depth of 1.6mm is adjusted to 80%, the sensitivity at the moment is set as reference sensitivity, gain values when the embedded depth of each flat bottom hole comparison sample is 80% are sequentially recorded, a TCG curve is drawn, the reference sensitivity is improved by 10dB after the manufacture is completed, and the detection sensitivity of phi 0.4mm-10dB is obtained;
3. ultrasonic detection blind area detection:
and (3) placing the raceway flat bottom hole sample prepared in the step one in a three-jaw chuck of a water immersion ultrasonic device for locking and centering, detecting the whole outer diameter surface of the raceway flat bottom Kong Shiyang by adopting a longitudinal wave vertical incidence outer diameter surface mode, and beating a probe focus on the outer diameter surface of the raceway flat bottom hole sample to obtain detection data, thereby completing the high-sensitivity small blind area ultrasonic detection of the bearing ring.
And in the first step, burrs caused by the flat bottom hole comparison sample in the processing are removed, and the upper edge and the lower edge are rounded.
In the third step, the water immersion ultrasonic equipment adopts a Scan Master disc ring ultrasonic water immersion detection system, the model LS-500, has a C scanning imaging function, and parameters are as follows: the detection sensitivity is phi 0.4mm-10dB equivalent flat bottom hole, and the pulse repetition frequency is 600Hz.
The probe in the third step adopts a longitudinal wave point focusing straight probe with the frequency of 10MHz, the wafer size of 0.43 inch and the focal length of 3.5 inches.
In the third step, the outer diameter surface is an ultrasonic incident surface, no impurity interfering with ultrasonic detection signals is required, the outer diameter surface is processed by adopting a round head cutter, and the surface is not provided with turning lines.
The invention has the following advantages:
aeroengine bearings are often used as important transmission components, and have high internal quality acceptance requirements, so that the sensitivity level requirements for ultrasonic detection are also very high. Meanwhile, the bearing has high requirements on surface and near-surface quality, and the near-surface blind area of ultrasonic detection is expected to be as small as possible. However, for ultrasonic detection, the presence of a near-surface blind zone is unavoidable, and as the detection sensitivity increases, the near-surface blind zone will also increase. Therefore, on the premise of ensuring that the requirement of high detection sensitivity is met, the blind area of ultrasonic detection is reduced as much as possible; the flat bottom Kong Shikuai is manufactured by combining a bearing ring forging processing mode, the detection sensitivity is set according to factors such as ultrasonic detection signal-to-noise ratio, material noise signal size and the like, flat bottom holes with equivalent phi of 0.4-10 dB are detected and controlled for the bearing ring at present, flat bottom holes are processed for measuring blind areas of the bearing ring, the signals of buried holes with the depth of 0.4mm from a back reflection surface at present are smaller, deep holes with the depth of 0.8mm are clearly visible, buried holes with the depth of 1.5mm from an incidence surface are clearly visible, and the reflection surface and the incidence surface blind areas can be determined at present. The blind area of the incident surface of the detection ferrule is 1.5mm, the blind area of the reflecting surface is 0.8mm, the total coverage of internal detection is ensured, the surface blind area of ultrasonic detection is reduced, and the defect control range is improved. The invention can accurately detect and locate the micro defects and ensure the detection quality of water immersion ultrasonic.
The invention is suitable for the high-sensitivity small blind area ultrasonic detection of the bearing ring.
Drawings
FIG. 1 is a schematic view of a raceway flat bottom hole sample in an embodiment, where 1 is labeled 1 at 1/4 channel width of the channel side; marking 2 as a processing point ditch bottom; marking 3 and 4, namely processing 5 flat bottom holes along the circumferential direction of the roller path, wherein the intervals of the holes are 5mm;
fig. 2 is a schematic diagram of detection of a longitudinal wave point focusing straight probe in an embodiment, where D is a wafer size, F is a focal length, H is a water distance=88.9mm, a is a position of a focus in water, a 'is a position of a focus in a detected piece, l is a depth of the focus in the detected piece, and l' is a depth of the focus in water;
FIG. 3 is a pictorial view of the outer race of the finished bearing ring in an embodiment;
fig. 4 is a schematic diagram of vertical incidence of longitudinal waves and detection of an auxiliary end face by using an outer diameter face in an embodiment, wherein an incidence direction 3 is a main ultrasonic incidence face, an incidence direction 1 is an auxiliary ultrasonic incidence face, and an incidence direction 2 is an auxiliary ultrasonic incidence face;
fig. 5 is an ultrasound C-scan in an example.
Detailed Description
The technical scheme of the invention is not limited to the specific embodiments listed below, and also includes any combination of the specific embodiments.
The first embodiment is as follows: the high-sensitivity small-blind-area ultrasonic detection method for the bearing ring of the embodiment is realized by the following steps:
1. sample preparation:
flat bottom hole comparative sample: the manufacturing material of the flat bottom hole comparison sample is that 8Cr4Mo4V is consistent with the ferrule to be detected, the processing state and the size are the same, and the processing size is as follows: 6 apertures are phi 0.4mm, the diameters are 50.8mm, the burial depths are 1.6mm, 3.2mm, 6.4mm, 12.7mm, 25.4mm and 38.1mm respectively, and the thicknesses are 8.0mm, 9.6mm, 12.8mm, 19.1mm, 31.8mm and 44.5mm respectively;
raceway flat bottom Kong Shiyang: taking rings to be detected, and manufacturing flat bottom holes with different burial depths and near surfaces, wherein the flat bottom holes have the aperture phi of 0.4mm, the hole depths of 0.4mm, 0.8mm, 1.6mm, 3.2mm, 5mm and 6.4mm respectively, and the hole intervals are 5mm in total, and are respectively positioned at the center position of the circular arc bottom of a channel of the rings to be detected and the distance between the center of the circular arc bottom of the channel and the edge of a roller path by 1/2;
2. device sensitivity adjustment:
the flat bottom hole comparison samples are sequentially arranged from thin to thick according to the thickness sequence, the reflection wave height of the flat bottom holes with the embedded depth of 1.6mm is adjusted to 80%, the sensitivity at the moment is set as reference sensitivity, gain values when the embedded depth of each flat bottom hole comparison sample is 80% are sequentially recorded, a TCG curve is drawn, the reference sensitivity is improved by 10dB after the manufacture is completed, and the detection sensitivity of phi 0.4mm-10dB is obtained;
3. ultrasonic detection blind area detection:
and (3) placing the raceway flat bottom hole sample prepared in the step one in a three-jaw chuck of a water immersion ultrasonic device for locking and centering, detecting the whole outer diameter surface of the raceway flat bottom Kong Shiyang by adopting a longitudinal wave vertical incidence outer diameter surface mode, and beating a probe focus on the outer diameter surface of the raceway flat bottom hole sample to obtain detection data, thereby completing the high-sensitivity small blind area ultrasonic detection of the bearing ring.
The immersion ultrasonic equipment in the third step of the embodiment is provided with an automatic scanning device, can finish the multi-axis accurate scanning and the profiling tracking of curved surfaces and complex surfaces by using a precise mechanical system, has an immersion ultrasonic imaging function, has a C scanning real-time imaging function in the detection process, and can judge and track and position defects.
In the third step of the embodiment, a longitudinal wave point focusing straight probe is adopted, the focusing area of the point focusing probe is larger in energy and high in sensitivity, the diameter of the focal sound beam is small, the resolution is good, and the signal to noise ratio is good.
The second embodiment is as follows: in the first embodiment, the burrs caused by the flat bottom hole comparison sample in the processing are removed, and the upper edge and the lower edge are rounded. The other is the same as in the first embodiment.
And a third specific embodiment: the first difference between the embodiment and the specific embodiment is that the water immersion ultrasonic equipment in the third step adopts a Scan Master disc ring piece ultrasonic water immersion detection system, model LS-500, has a C scanning imaging function, and parameters: the detection sensitivity is phi 0.4mm-10dB equivalent flat bottom hole, and the pulse repetition frequency is 600Hz. The other is the same as in the first embodiment.
The specific embodiment IV is as follows: in the third step, the probe is a longitudinal wave point focusing straight probe with a frequency of 10MHz, a wafer size of 0.43 inch, and a focal length of 3.5 inches. The other is the same as in the first embodiment.
Fifth embodiment: the first difference between the present embodiment and the specific embodiment is that the outer diameter surface in the third step is an ultrasonic incident surface, no impurity interfering with ultrasonic detection signals is required, the outer diameter surface should be processed by a round head cutter, and no turning lines should be formed on the surface. The other is the same as in the first embodiment.
Noise interference caused by turning lines in the present embodiment.
The beneficial effects of the invention are verified by the following examples:
examples:
the bearing ring high-sensitivity small-blind-area ultrasonic detection method is realized by the following steps:
1. sample preparation:
flat bottom hole comparative sample: the manufacturing material of the flat bottom hole comparison sample is that 8Cr4Mo4V is consistent with the ferrule to be detected, the processing state and the size are the same, and the processing size is as follows: 6 apertures are phi 0.4mm, the diameters are 50.8mm, the burial depths are 1.6mm, 3.2mm, 6.4mm, 12.7mm, 25.4mm and 38.1mm respectively, and the thicknesses are 8.0mm, 9.6mm, 12.8mm, 19.1mm, 31.8mm and 44.5mm respectively;
raceway flat bottom Kong Shiyang: taking rings to be detected, and manufacturing flat bottom holes with different burial depths and near surfaces, wherein the flat bottom holes have the aperture phi of 0.4mm, the hole depths of 0.4mm, 0.8mm, 1.6mm, 3.2mm, 5mm and 6.4mm respectively, and the hole intervals are 5mm in total, and are respectively positioned at the center position of the circular arc bottom of a channel of the rings to be detected and the distance between the center of the circular arc bottom of the channel and the edge of a roller path by 1/2;
2. device sensitivity adjustment:
the flat bottom hole comparison samples are sequentially arranged from thin to thick according to the thickness sequence, the reflection wave height of the flat bottom holes with the embedded depth of 1.6mm is adjusted to 80%, the sensitivity at the moment is set as reference sensitivity, gain values when the embedded depth of each flat bottom hole comparison sample is 80% are sequentially recorded, a TCG curve is drawn, the reference sensitivity is improved by 10dB after the manufacture is completed, and the detection sensitivity of phi 0.4mm-10dB is obtained;
3. ultrasonic detection blind area detection:
and (3) placing the raceway flat bottom hole sample prepared in the step one in a three-jaw chuck of a water immersion ultrasonic device for locking and centering, detecting the whole outer diameter surface of the raceway flat bottom Kong Shiyang by adopting a longitudinal wave vertical incidence outer diameter surface mode, and beating a probe focus on the outer diameter surface of the raceway flat bottom hole sample to obtain detection data, thereby completing the high-sensitivity small blind area ultrasonic detection of the bearing ring.
In the first embodiment, burrs caused by the flat bottom hole comparison sample in the processing are removed, and the upper edge and the lower edge are rounded.
In the first embodiment, the material of the ferrule to be inspected is 8Cr4Mo4V.
In the third step of the embodiment, the water immersion ultrasonic equipment adopts a Scan Master disc ring ultrasonic water immersion detection system, model LS-500, has a C-scanning imaging function, and parameters: the detection sensitivity is phi 0.4mm-10dB equivalent flat bottom hole, and the pulse repetition frequency is 600Hz.
In the third step of this embodiment, the probe is a longitudinal wave point focusing straight probe with a frequency of 10MHz, a wafer size of 0.43 inch, and a focal length of 3.5 inches.
In the third step of the embodiment, the outer diameter surface is an ultrasonic incident surface, no impurity interfering with ultrasonic detection signals is required, the outer diameter surface is processed by adopting a round head cutter, and the surface is not provided with turning lines.
In the first embodiment, the schematic view of the raceway flat bottom Kong Shiyang is shown in fig. 1, and it can be seen that the center position of the bottom of the circular arc of the raceway channel of the ferrule to be inspected is 1/2 distance from the bottom center of the circular arc of the raceway channel to the raceway edge; wherein the raceway edge is at a distance of 1/2, i.e. the position marked 1 in fig. 1, i.e. the channel width of the channel side 1/4; the position marked as 2 is the bottom of the processing point ditch; the marks 3 and 4 are 5 flat bottom holes processed along the circumferential direction of the roller path, and the intervals of the holes are 5mm.
In this embodiment, the detection schematic diagram of the longitudinal wave point focusing straight probe is shown in fig. 2, where D is the wafer size, F is the focal length, H is the water distance=88.9mm, a is the position of the focus in water, a 'is the position of the focus in the detected piece, l is the depth of the focus in the detected piece, and l' is the depth of the focus in water.
In the second step of this embodiment, verification is performed after the device sensitivity is adjusted:
test pieces with different surface roughness are prepared, and the back reflection wave height condition and the ultrasonic effect of noise signals are tested. Because the surface roughness of the actual forging collar is good, the test is carried out by utilizing the real object of the on-site forging collar. During detection, the ferrule is placed in a three-jaw chuck to be locked and self-centered, the turntable rotates, a focus of the water immersion ultrasonic probe is beaten on the surface of the outer diameter, and the probe is vertically incident on the outer diameter and vertically scanned in a stepping mode along the outer diameter direction; the 3 ferrules to be tested are marked 1,2 and 3, respectively.
The preparation is shown in Table 1:
| numbering device | Outer diameter (mm) | Roughness of incident surface μm |
| 1# | 137 | 0.443 |
| 2# | 183 | 0.326 |
| 3# | 225 | 0.652 |
The verification results are shown in table 2: under the current test result, the noise signal with the larger noise signal of-10 dB is 16%, the noise signal is close to the upper limit of 20%, the gain number which can be improved is small, the noise is obviously increased or even eliminated under the condition of actual increase, and the sensitivity space which can be improved is small because the surface roughness of the part is small. Due to the limitation of detection materials, the increase of noise of the materials obviously affects the accurate identification of detection signals after the detection sensitivity is increased, and the signal to noise ratio is reduced.
TABLE 2
In the embodiment, ultrasonic detection blind area detection is carried out, a longitudinal wave direct incidence method is adopted to test the defect surface and the surface blind area of a flat bottom hole, transmission correction and ultrasonic signal waveform analysis corresponding to the defect are carried out, finally, a water immersion point focusing longitudinal wave probe with the diameter of 10MHz, the diameter of a wafer of 0.43 inch and the focal length of 3.5 inches is determined, phi 0.4mm-10dB is used as detection sensitivity, a higher frequency probe is influenced by surface noise and material grains, and clutter is relatively high. The finished ferrule is an outer ring (figure 3), the outer diameter surface is selected for vertical incidence of sound waves, and end face detection is assisted (figure 4, wherein the incidence direction 3 is a main ultrasonic incidence surface, the incidence direction 1 is an auxiliary ultrasonic incidence surface, and the incidence direction 2 is an auxiliary ultrasonic incidence surface).
The detection is carried out by adopting the vertical incidence of the outer diameter surface, the result is that the defect position on the test piece is effectively detected, the ultrasonic C scanning chart is shown in figure 5, and the test shows that the detection has certain identification on the flat bottom hole with the depth of 0.4mm on the raceway surface of the finished bearing ring, but the signal is slightly weak, but the hole signal of 0.8mm is larger, so that the ultrasonic detection on the back reflection surface is relatively ideal, and the ultrasonic C scanning chart can be controlled at 0.8mm. The blind area of the incidence surface can be calculated to have a flat bottom hole distance of 1.5mm according to the thickness of the middle position of the rollaway nest of 7.9mm, the hole signal is larger, and the blind area of the incidence surface can reach 1.5mm when the signal to noise ratio is higher.
Claims (2)
1. The bearing ring high-sensitivity small-blind-area ultrasonic detection method is characterized by comprising the following steps of:
1. sample preparation:
flat bottom hole comparative sample: the manufacturing material of the flat bottom hole comparison sample is that 8Cr4Mo4V is consistent with the ferrule to be detected, the processing state and the size are the same, and the processing size is as follows: 6 apertures are phi 0.4mm, the diameters are 50.8mm, the burial depths are 1.6mm, 3.2mm, 6.4mm, 12.7mm, 25.4mm and 38.1mm respectively, and the thicknesses are 8.0mm, 9.6mm, 12.8mm, 19.1mm, 31.8mm and 44.5mm respectively;
raceway flat bottom Kong Shiyang: taking rings to be detected, and manufacturing flat bottom holes with different burial depths and near surfaces, wherein the flat bottom holes have the aperture phi of 0.4mm, the hole depths of 0.4mm, 0.8mm, 1.6mm, 3.2mm, 5mm and 6.4mm respectively, and the hole intervals are 5mm in total, and are respectively positioned at the center position of the circular arc bottom of a channel of the rings to be detected and the distance between the center of the circular arc bottom of the channel and the edge of a roller path by 1/2;
2. device sensitivity adjustment:
the flat bottom hole comparison samples are sequentially arranged from thin to thick according to the thickness sequence, the reflection wave height of the flat bottom holes with the embedded depth of 1.6mm is adjusted to 80%, the sensitivity at the moment is set as reference sensitivity, gain values when the embedded depth of each flat bottom hole comparison sample is 80% are sequentially recorded, a TCG curve is drawn, the reference sensitivity is improved by 10dB after the manufacture is completed, and the detection sensitivity of phi 0.4mm-10dB is obtained;
3. ultrasonic detection blind area detection:
the raceway flat bottom hole sample prepared in the first step is placed in a three-jaw chuck of a water immersion ultrasonic device for locking and centering, the whole outer diameter surface of a raceway flat bottom Kong Shiyang is detected by adopting a longitudinal wave vertical incidence outer diameter surface mode, and a probe focus is punched on the outer diameter surface of the raceway flat bottom hole sample to obtain detection data, so that high-sensitivity small blind area ultrasonic detection of the bearing ring is completed;
the ultrasonic immersion equipment in the third step adopts a Scan Master disc ring ultrasonic immersion detection system, model LS-500, and has a C scanning imaging function and parameters: the detection sensitivity is phi 0.4mm-10dB equivalent flat bottom hole, and the pulse repetition frequency is 600Hz;
in the third step, the probe adopts a longitudinal wave point focusing straight probe with the frequency of 10MHz, the wafer size of 0.43 inch and the focal length of 3.5 inch;
in the third step, the outer diameter surface is an ultrasonic incidence surface, no impurity interfering with ultrasonic detection signals is required, the outer diameter surface is processed by adopting a round head cutter, and the surface is not provided with turning lines.
2. The ultrasonic detection method for the high-sensitivity small dead zone of the bearing ring, which is characterized in that burrs caused by the flat bottom hole comparison sample in the processing in the step one are removed, and the upper edge and the lower edge are rounded.
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| JP6263665B1 (en) * | 2017-01-24 | 2018-01-17 | 住友化学株式会社 | Pseudo-defect sample and manufacturing method thereof, adjustment method of ultrasonic flaw detection measurement conditions, target material inspection method, and sputtering target manufacturing method |
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