CN114324576A - Method and device for detecting dark cracks of metal plate stamping part - Google Patents
Method and device for detecting dark cracks of metal plate stamping part Download PDFInfo
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- CN114324576A CN114324576A CN202110334034.4A CN202110334034A CN114324576A CN 114324576 A CN114324576 A CN 114324576A CN 202110334034 A CN202110334034 A CN 202110334034A CN 114324576 A CN114324576 A CN 114324576A
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Abstract
The invention provides a dark crack detection device for a metal sheet stamping part, which comprises an excitation generation device, a coil, a magnet, an echo receiving device and a signal processing device. The invention generates ultrasonic waves by exciting the surface of the part to be detected through high-frequency exciting current, realizes the dark crack detection of the part formed by stamping the metal plate through ultrasonic echo signals, realizes the nondestructive detection, does not generate any damage to the part to be detected, has high efficiency, does not leak the detection and realizes the automatic detection.
Description
Technical Field
The invention relates to the technical field, in particular to a method and a device for detecting dark cracks of a metal plate stamping part.
Background
The defects of cracking and dark cracking can be generated in the process of stamping and forming metal parts, and the main reason is that the actual tensile stress borne by the material exceeds the tensile limit of the material at the cracking position in the process of stamping, processing and stretching deformation of the plate material, the local yield of the material is reduced in neck but not cracked, and the dark cracking defect which cannot be observed by naked eyes occurs. After the metal plate is stamped and formed, the hidden danger of parts needs to be found in time in a quick and effective online detection mode, unqualified parts are removed, and the product percent of pass and the product quality are improved. The method is also beneficial to judging the technical problems of the material and the die of the stamping part by finding the dark crack of the part in time, and improves the stamping production technical level.
In the traditional method for detecting the dark cracks of the parts, the light method is generally used for detecting the dark cracks in a production workshop, the parts possibly having the dark cracks are irradiated by light, whether the hidden dark cracks exist is determined according to the reflection of the light and the dark shadow condition, and suspicious parts of the parts need to be polished for improving the observation effect.
Disclosure of Invention
In view of the above, on the one hand, the invention provides a device for detecting a blind crack of a metal plate stamping part, so as to solve the problems that the traditional device for detecting a blind crack of a metal plate stamping part is low in efficiency, high in missing detection rate and difficult to realize automatic detection.
The technical scheme of the invention is realized as follows: a dark crack detection device for a metal sheet stamping part comprises an excitation generation device, a coil, a magnet, an echo receiving device and a signal processing device;
the coil and the magnet are close to the part to be detected and are arranged at the same position of the part to be detected, a gap is formed between the coil and the surface of the part to be detected, and the magnet is used for applying a magnetic field to the surface of the part to be detected;
the excitation generating device is electrically connected with the coil and used for generating high-frequency excitation current and acting on the coil;
the echo receiving device is electrically connected with the coil and used for receiving an echo signal generated on the coil;
the signal processing device is electrically connected with the echo receiving device and used for positioning the dark crack defect of the part to be detected according to the echo signal and quantifying the dark crack degree of the dark crack defect.
Optionally, the magnet is one of a permanent magnet, a dc electromagnet, an ac electromagnet, and a pulse electromagnet.
Optionally, the dark crack detection device is applied to a part to be detected with the thickness of 1.0-6.0 mm, and the gap between the coil and the surface of the part to be detected is 0.15-0.5 mm.
Optionally, the frequency of the high-frequency excitation current is 430-470 kHz.
Optionally, the dark crack detection device is applied to parts to be detected formed by long shafts and plane symmetric plates, and the frequency of the high-frequency excitation current is 350-500 kHz.
Compared with the prior art, the dark crack detection device has the following beneficial effects:
(1) the ultrasonic wave is generated by exciting the surface of the part to be detected through the high-frequency exciting current, the dark crack detection of the part formed by stamping the metal plate is realized through the ultrasonic wave echo signal, the nondestructive detection is realized, the position and the degree of the dark crack defect can be positioned, the part to be detected is not damaged, the efficiency is high, the detection omission is avoided, and the automatic detection is realized.
(2) Because the ultrasonic wave is generated by the part self-excitation, a coupling agent is not required to be filled between the detection device and the part to be detected, and the surface state of the part to be detected is not changed;
(3) according to different response characteristics of ultrasonic signals to the sizes of the invisible defects of the part to be detected, the echo characteristics of slight necking, moderate necking and severe necking (cracking) generated after the part is formed are established and used as quantitative criteria of the invisible defects (dark cracking), and the degree of the invisible defects of the part to be detected is obtained, so that data information from small dark cracking to large dark cracking to breakage is expressed.
On the other hand, the invention also provides a method for detecting the blind crack of the metal plate stamping part, so as to solve the problems of low efficiency, high missing rate and difficulty in realizing automatic detection of the traditional method for detecting the blind crack of the metal plate stamping part.
The technical scheme of the invention is realized as follows: a method for detecting the hidden crack of a metal plate stamping part comprises the following steps:
step S1, the excitation generating device applies high-frequency excitation current to a coil on the surface of a comparison standard part without hidden defects, the echo receiving device receives echo signals generated on the coil on the surface of the comparison standard part, and the signal processing device sets the echo signals generated on the coil on the surface of the comparison standard part as comparison standard signals;
step S2, applying high-frequency excitation current to a coil on the surface of the part to be detected by an excitation generating device, receiving an echo signal generated on the coil on the surface of the part to be detected by an echo receiving device, and setting the echo signal generated on the coil on the surface of the part to be detected as a target echo signal by a signal processing device;
and step S3, the signal processing device compares the target echo signal with the reference standard signal, positions the dark crack defect of the part to be detected, and quantifies the dark crack degree of the dark crack defect.
Optionally, step S3 includes:
determining an edge reflection echo in the comparison standard signal, and comparing the target echo signal with the comparison standard signal to determine a dark crack echo in the target echo signal;
and positioning the dark crack defect of the part to be detected according to the echo time difference between the edge reflection echo and the dark crack echo.
Optionally, step S3 further includes:
and quantifying the dark crack degree of the dark crack defect according to the energy of the dark crack echo.
Optionally, quantifying the dark crack degree of the dark crack defect according to the energy of the dark crack echo, including:
if the energy of the dark crack echo is a, quantifying the dark crack degree of the dark crack defect to be light necking;
if the energy of the dark crack echo is b, quantifying the dark crack degree of the dark crack defect to be moderate necking;
if the energy of the dark crack echo is c, quantifying the dark crack degree of the dark crack defect as severe necking or cracking;
wherein a < b < c.
The advantages of the dark crack detection method and the dark crack detection device are similar to those of the prior art, and are not described herein again.
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 a dark crack detection device according to the present invention;
FIG. 2 is a schematic diagram of the dark crack detection principle of the present invention;
FIG. 3 is a flow chart of a dark crack detection method of the present invention;
FIG. 4 is a diagram of an experimental example of the dark crack detection device of the present invention;
FIG. 5 is a comparison graph of echo signals generated on a reference standard part and a part to be measured according to the present invention;
FIG. 6 is a graph of echo signals generated on a reference standard part of the present invention;
FIG. 7 is a diagram of echo signals generated on a part under test according to the present invention.
Description of reference numerals:
1-a coil; 2-magnet.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention.
As shown in fig. 1, the device for detecting a blind crack of a sheet metal stamping part according to the present embodiment includes an excitation generating device, a coil 1, a magnet 2, an echo receiving device, and a signal processing device.
Wherein, the magnet 2 is one of a permanent magnet, a direct current electromagnet, an alternating current electromagnet and a pulse electromagnet.
The principle of the dark crack detection device of the embodiment is as follows: when high-frequency excitation current generated by the excitation generating device acts on the coil 1, eddy current with corresponding frequency is induced on the surface of the part formed by stamping the metal plate, a magnetic field is applied to the same position on the surface of the part to be detected by the magnet 2, the eddy current generates a force with the same frequency as the eddy current under the action of the magnetic field, namely Lorentz force, and the Lorentz force is propagated in the part to be detected to form ultrasonic wave. Because the effect is reversible, when ultrasonic signals propagate in the part to be detected and encounter a sudden change in plate thickness or a structural defect (crack or necking), the reflected ultrasonic echo signals also generate eddy currents under the action of an external magnetic field, and the eddy current magnetic field can change the end voltage of a coil, so that the sudden change in plate thickness or the structural defect can be detected by detecting the ultrasonic echo signals, and the dark crack defect of the part to be detected and the dark crack degree of the dark crack defect can be positioned and quantified.
As shown in fig. 2, the emitted ultrasonic surface wave signal propagates in the part to be measured, one part of the ultrasonic surface wave signal is reflected when encountering a dark crack defect to form a reflected wave, i.e., a dark crack echo, and the other part of the ultrasonic surface wave signal is transmitted through the defect from the lower part of the dark crack defect to form a transmitted wave.
Therefore, according to the above principle, as shown in fig. 3, the present embodiment provides a method for detecting a blind crack of a part formed by stamping a metal plate, including:
step S1, the excitation generating device applies high-frequency excitation current to a coil on the surface of a comparison standard part without hidden defects, the echo receiving device receives echo signals generated on the coil on the surface of the comparison standard part, and the signal processing device sets the echo signals generated on the coil on the surface of the comparison standard part as comparison standard signals;
step S2, applying high-frequency excitation current to a coil on the surface of the part to be detected by an excitation generating device, receiving an echo signal generated on the coil on the surface of the part to be detected by an echo receiving device, and setting the echo signal generated on the coil on the surface of the part to be detected as a target echo signal by a signal processing device;
and step S3, the signal processing device compares the target echo signal with the reference standard signal, positions the dark crack defect of the part to be detected, and quantifies the dark crack degree of the dark crack defect. In step S3, the method for determining the dark crack defect of the part to be measured includes: determining an edge reflection echo in the comparison standard signal, and comparing the target echo signal with the comparison standard signal to determine a dark crack echo in the target echo signal; and positioning the dark crack defect of the part to be detected according to the echo time difference between the edge reflection echo and the dark crack echo.
As shown in fig. 4, in the step S2, when the part to be tested is tested, the coil may be disposed at point a, where point a may be located at the middle position of the major and minor axes of the part, or at an end position of the symmetry axis. An ultrasonic signal excited by the excitation current generated by the point A is transmitted along the surface of the part to be measured, and the dark crack defect occurs at the point B.
Because the ultrasonic signal is reflected when encountering a sudden change in plate thickness, that is, when encountering the edge of the part to be measured, a reflected wave (edge reflection echo) is also generated, the echo signal received by the signal processing device includes both the edge reflection echo and the dark crack echo. Before the dark crack defect of the part to be detected is located according to the echo signal generated on the surface coil of the part to be detected, the edge reflection echo and the dark crack echo in the echo signal need to be determined and distinguished.
The reference standard part without the hidden defect and the part to be detected are the same part, and the mounting positions of the hidden crack detection device and the hidden crack detection device are the same. The echo signals generated on the surface coil of the reference standard part without hidden defects do not include dark crack echoes, and only include edge reflection echoes, as shown in fig. 5. In this embodiment, after the echo signal generated on the coil on the surface of the reference standard part is acquired and set as the reference standard signal in step S1, the edge reflection echo in the reference standard signal can be directly determined according to the reference standard signal. Because the echo signals generated on the surface coil of the part to be detected generally comprise two types of edge reflection echoes and dark crack echoes, although the energies of the two edge reflection echoes in the comparison standard signal and the target echo signal are possibly different, the echo time of the two edge reflection echoes is always the same, and the edge reflection echo in the target echo signal can be determined according to the echo time of the two edge reflection echoes. The echo in the further target echo signal that is increased compared to the control standard signal is a dark split echo, as shown in fig. 6 and 7. If the point B in the graph 4 has the dark crack defect, part of reflected waves return in advance to form a dark crack echo, and finally the dark crack defect of the part to be detected can be located according to the echo time difference between the edge reflected echo and the dark crack echo. The edge of the part to be measured is known, the speed of the ultrasonic wave is known, and the product of the echo time difference of the edge reflection echo and the dark crack echo and the ultrasonic wave speed is the distance between the dark crack defect position and the edge of the part to be measured.
In the experiment, the deeper the depth of the dark crack defect of the part to be detected is, the larger the dark crack echo energy in the target echo signal is, and the relatively weakened energy of the transmitted wave is, so that the dark crack degree of the dark crack defect of the part to be detected can be indirectly obtained through monitoring the dark crack echo and the transmitted wave energy. Step S3 thus further includes: quantifying the dark crack degree of the dark crack defect according to the energy of the dark crack echo, specifically, if the energy of the dark crack echo is a, quantifying the dark crack degree of the dark crack defect to be slight necking; if the energy of the dark crack echo is b, quantifying the dark crack degree of the dark crack defect to be moderate necking; if the energy of the dark crack echo is c, quantifying the dark crack degree of the dark crack defect as severe necking or cracking: wherein a < b < c. The values a, b and c can be specific values or range intervals, and different types of parts to be tested have different values a, b and c. Because the deeper the depth of the dark crack defect of the part to be detected is, the larger the dark crack echo energy in the target echo signal is, the echo characteristics of mild necking, moderate necking and severe necking (cracking) generated after the part is formed are established according to different response characteristics of ultrasonic signals to the size of the invisible defect of the part to be detected, the echo characteristics are used as quantitative criteria of the invisible defect (dark crack), the degree of the invisible defect of the part to be detected and the influence on the serviceability of the part are obtained, and therefore data information from small dark crack to large dark crack to fracture is expressed.
Therefore, the ultrasonic wave is generated by exciting the surface of the part to be detected through the high-frequency exciting current, the dark crack detection of the part formed by stamping the metal plate is realized through the ultrasonic wave echo signal, the nondestructive detection is realized, the part to be detected is not damaged, the efficiency is high, the detection omission is avoided, and the automatic detection is realized. Because the ultrasonic wave is generated by the part self-excitation, a coupling agent is not required to be filled between the detection device and the part to be detected, and the surface state of the part to be detected is not changed.
The device and the method for detecting the dark cracks can be used for detecting defects of folding, heavy skin, holes and the like of metal plate forming parts. The magnitude of the exciting current can directly influence the magnitude of the surface induced eddy current of the part, and the Lorentz force formula shows that the magnitude of the exciting current can be changed to remarkably increase the amplitude of the surface wave displacement, so that the amplitude of the induced voltage at the echo receiving device is increased, and the defect detection efficiency is improved. Since the dark cracks (necking of material) start from the surface of the slab, as the load approaches or exceeds the strength limit, in order to improve the detection sensitivity of the micro dark cracks, it is necessary to increase the strength of the surface wave, thereby improving the resolution of the degree of dark cracks. When the current is smaller, the amplitude change of the surface wave displacement is slower, and when the current is larger, the amplitude change of the surface wave displacement is larger. The amplitude of the ultrasonic wave exhibits an exponential decay with an increase in the lift-off distance. Therefore, the current parameters can be optimized, the gap distance between the coil and the part is reduced as much as possible, the amplitude of the echo signal is improved, and the defect detection efficiency is improved.
In addition, different excitation current frequencies have different influences on the surface wave amplitude generated in the part, and the surface wave amplitude is increased and then reduced along with the increase of the excitation current frequency. For parts with different thicknesses, the frequency of the peak value of the excited surface wave can be obtained by performing frequency scanning on the excitation current. When the method is applied to the part to be measured with the thickness of 1.0-6.0 mm, the surface wave amplitude reaches the maximum value when the excitation current frequency is 430-470 kHz, and the comprehensive efficiency of electromagnetic wave excitation and reflected wave receiving is the best when the gap between the coil and the surface of the part to be measured is 0.15-0.5 mm under the room temperature condition. When the high-frequency excitation current source is applied to parts to be measured formed by long shafts and plane symmetric plates, the frequency of the high-frequency excitation current is 350-500 kHz, and the high-frequency excitation current source has the best effect.
In addition, when the width of the dark crack defect is constant, the change of the reflection coefficient curved surface is relatively uniform before the depth of the dark crack defect is 0.5 times of the wavelength, incident waves are scattered and transmitted along with the increase of the depth of the dark crack defect, and the change fluctuation of the reflection coefficient curved surface is relatively large. When the width of the dark crack defect is constant, the surface wave change fluctuation of the surface wave transmission coefficient is smaller than that of the reflection coefficient surface along with the increase of the depth of the dark crack defect, and the transmission coefficient basically has exponential attenuation trend along with the increase of the depth of the defect, so that the method is more suitable for quantifying the dark crack defect.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (9)
1. A dark crack detection device for a metal sheet stamping part is characterized by comprising an excitation generation device, a coil, a magnet, an echo receiving device and a signal processing device;
the coil and the magnet are close to the part to be detected and are arranged at the same position of the part to be detected, a gap is formed between the coil and the surface of the part to be detected, and the magnet is used for applying a magnetic field to the surface of the part to be detected;
the excitation generating device is electrically connected with the coil and used for generating high-frequency excitation current and acting on the coil;
the echo receiving device is electrically connected with the coil and used for receiving an echo signal generated on the coil;
the signal processing device is electrically connected with the echo receiving device and used for positioning the dark crack defect of the part to be detected according to the echo signal and quantifying the dark crack degree of the dark crack defect.
2. The apparatus of claim 1, wherein the magnet is one of a permanent magnet, a dc electromagnet, an ac electromagnet, and a pulse electromagnet.
3. The device for detecting the blind cracks of the metal plate stamping part as claimed in claim 1, wherein the device for detecting the blind cracks is applied to the part to be detected with the thickness of 1.0-6.0 mm, and the gap between the coil and the surface of the part to be detected is 0.15-0.5 mm.
4. The device for detecting the dark cracks of the metal plate stamping part as claimed in claim 3, wherein the frequency of the high-frequency excitation current is 430-470 kHz.
5. The device for detecting the dark cracks of the metal plate stamping parts as claimed in claim 1, wherein the device for detecting the dark cracks is applied to parts to be detected formed by long-axis and plane symmetric plates, and the frequency of the high-frequency excitation current is 350-500 kHz.
6. A dark crack detection method for a metal plate stamping part is characterized by comprising the following steps:
step S1, the excitation generating device applies high-frequency excitation current to a coil on the surface of a comparison standard part without hidden defects, the echo receiving device receives echo signals generated on the coil on the surface of the comparison standard part, and the signal processing device sets the echo signals generated on the coil on the surface of the comparison standard part as comparison standard signals;
step S2, applying high-frequency excitation current to a coil on the surface of the part to be detected by an excitation generating device, receiving an echo signal generated on the coil on the surface of the part to be detected by an echo receiving device, and setting the echo signal generated on the coil on the surface of the part to be detected as a target echo signal by a signal processing device;
and step S3, the signal processing device compares the target echo signal with the reference standard signal, positions the dark crack defect of the part to be detected, and quantifies the dark crack degree of the dark crack defect.
7. The apparatus for detecting blind cracks in sheet metal stamped and formed parts according to claim 6, wherein step S3 includes:
determining an edge reflection echo in the comparison standard signal, and comparing the target echo signal with the comparison standard signal to determine a dark crack echo in the target echo signal;
and positioning the dark crack defect of the part to be detected according to the echo time difference between the edge reflection echo and the dark crack echo.
8. The apparatus for detecting blind cracks in sheet metal stamped and formed parts according to claim 7, wherein step S3 further comprises:
and quantifying the dark crack degree of the dark crack defect according to the energy of the dark crack echo.
9. The apparatus of claim 8, wherein quantifying the extent of dark cracking in the dark crack defect based on the energy of the dark crack echo comprises:
if the energy of the dark crack echo is a, quantifying the dark crack degree of the dark crack defect to be light necking;
if the energy of the dark crack echo is b, quantifying the dark crack degree of the dark crack defect to be moderate necking;
if the energy of the dark crack echo is c, quantifying the dark crack degree of the dark crack defect as severe necking or cracking;
wherein a < b < c.
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