CN115586257A - Intelligent defect identification and evaluation method for ultrasonic automatic detection of composite material - Google Patents
Intelligent defect identification and evaluation method for ultrasonic automatic detection of composite material Download PDFInfo
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Abstract
The invention provides an intelligent defect identification and evaluation method for ultrasonic automatic detection of a composite material, belongs to the technical field of nondestructive detection, and qualitatively and quantitatively detects defects in variable-thickness parts by using a stable and reliable automatic detection means. The invention provides a new effective analysis interval in an ultrasonic time domain range and an intelligent identification principle based on defect multi-view imaging of the effective analysis interval, and is suitable for various composite material workpieces with variable thicknesses, such as laminate workpieces, interlayer workpieces and the like. The method can visually reflect the whole thickness and structural change of the part, comprehensively acquire the ultrasonic signals and image, and avoid missing detection and judgment; the method is simple, convenient and quick to operate, can effectively eliminate the influence of human factors on the detection accuracy, saves the manual analysis time, enables the detection result to be more reliable and improves the detection efficiency; the method is strong in universality and convenient to operate, and is suitable for engineering application of automatic ultrasonic detection of the composite material.
Description
Technical Field
The invention belongs to the technical field of nondestructive testing, relates to an intelligent defect identification and evaluation method for ultrasonic automatic testing of composite materials, in particular to an intelligent identification and evaluation strategy for multi-view imaging of typical defects of ultrasonic automatic testing, and discloses an automatic defect identification method for composite material workpieces for detecting thickness changes.
Background
With the acceleration of the lightweight process in the aerospace field, the amount of composite materials is continuously increasing and becomes the main material of the aircraft structure, and the application of a large amount of composite materials becomes an important mark for measuring the advancement of the technical level of a new-generation aircraft. However, for the composite material, due to the influence of the surface state of the fiber, the viscosity of the resin, the content of low molecular weight substances, the chemical reaction speed of the linear high polymer to the bulk high polymer, the impregnability of the resin and the fiber, the difference of the thermal expansion coefficients of the component materials, the control of process parameters and the like, various harmful defects such as layering, debonding, inclusion, porosity and the like, which are generated during the structural molding, assembly and service stages inevitably can seriously affect various performances of the part no matter what process method is used for manufacturing. Ultrasonic detection is the most practical and effective nondestructive detection technology which is most widely applied to composite materials at present, and can reliably detect most of harmful defects such as layering, looseness, pores and the like in the composite materials.
With the increasing demand of composite materials in the field of aviation, the industry has raised higher requirements for the detection of these harmful defects, and not only is the precise positioning of the defects and the reliable identification of the defect types required to be realized, but also an automatic detection means is required to be used to ensure the detection efficiency. For ultrasonic detection of composite parts with complex and variable structures, the difficulty in realizing automation for reliable identification of defect types is high. The traditional automatic signal acquisition mode of metal materials is to image defect waves independently, and the defect condition inside parts is represented by arranging a gate between surface echo and structure echo (such as bottom wave). If the thickness of the material changes, the time domain position of the bottom wave needs to be tracked in real time through software, and the length of the elastic gate is adjusted along with the position of the bottom wave, so that the defect monitoring of the thickness change area is realized. Because the defects needing to be monitored in the composite material are generally large and the bottom waves of parts do not always exist stably, the elastic gate with the variable length arranged along with the wandering of the bottom wave position in the traditional mode cannot be implemented; in China, a method for obtaining the position of the transducer by learning through a neural network so as to calculate the thickness of a sampling point and then adjust the width of the gate is also researched, but the method is relatively complex and has poor universality. Therefore, a general intelligent identification method for reliably identifying the defects during the ultrasonic detection by the automatic reflection method needs to be developed for the composite material, so that the defects of the traditional signal acquisition mode can be overcome, the universality and the applicability of the automatic defect identification can be improved, and the automatic detection efficiency can be really improved.
Disclosure of Invention
Aiming at the ultrasonic detection process of the automatic reflection method of the composite material workpiece, the invention provides a new effective analysis interval in an ultrasonic time domain range and an intelligent identification principle of defect multi-view imaging based on the effective analysis interval. The method is suitable for various composite material products of laminate products (including a laminated structure area and a board bonding structure area), sandwich products (including a honeycomb sandwich structure area and a foam sandwich structure area) and the like with variable thicknesses.
Firstly, determining an effective analysis interval according to the thickness variation range of a variable-thickness part, and arranging a gate containing the effective analysis interval, wherein the gate has a starting position which is a surface echo and a bottom wave position with the width being the maximum thickness of the part, and the height of the gate is slightly higher than a noise signal so as to ensure that signals except system noise can be acquired; then, the modes of signal triggering in the gate are respectively set as "first wave peak sound time", "first wave peak amplitude", "highest wave peak sound time", "highest wave peak amplitude", "tail wave peak sound time", and "tail wave peak amplitude", as shown in fig. 1, the position where the gate a 5 acquires the ultrasonic signal in fig. 1 is the first wave peak 8, the position where the gate b6 acquires the ultrasonic signal is the highest wave peak 9, and the position where the gate c 7 acquires the ultrasonic signal is the tail wave peak 10, in fig. 1, the actual heights of the gate a 5, the gate b6, and the gate c 7 are the same, and the positions are mutually overlapped, for the purpose of distinguishing and explaining, as shown in fig. 1. Typical defect types such as layering, debonding, inclusion, dense gaps, resin enrichment, air holes and the like in the composite material can be found through a multi-view imaging defect intelligent identification principle according to the C scanning image generated by the signal acquisition mode set for the variable-thickness part.
In order to achieve the purpose, the technical scheme of the invention is as follows:
an intelligent defect identification and evaluation method for ultrasonic automatic detection of composite materials is an automatic identification method for detecting defects in composite materials with variable thicknesses, and comprises the following steps:
step one, determining an effective analysis interval; before the detection is started, the transducer is placed at the position of the area with the largest whole thickness of the part for scanning, the time domain position of the bottom wave 4 in the ultrasonic A scanning waveform is observed, and the time domain range from the surface echo 1 to the position behind the bottom wave 4 is the effective analysis interval for judging the part defects.
The effective analysis interval provided by the present invention refers to an interval from the surface echo 1 to the bottom wave 4 (including the bottom wave 4) in the time domain position, that is, the outer circle large frame range shown in fig. 2, and the waveforms shown in fig. 2 sequentially include the surface echo 1, the defect wave 2, the structure echo 3, and the bottom wave 4 from left to right. The innovation point is that the ultrasonic signals collected in the interval can reflect the thickness and structure change of the part and the defect information in the part in the C scanning image.
Step two, setting detection parameters and a signal acquisition gate of the automatic reflection method ultrasonic detection system; adjusting the angle of a transducer, enabling the incident axis of ultrasonic waves to be vertical to the surface of a comparison test block, setting a Time Correction Gain (TCG) curve according to the amplitude heights of bottom waves of a plurality of thickness steps in the comparison test block, setting 3 gates in an effective analysis interval, setting the initial position, the width and the height of the gate and the signal acquisition mode of the gate, adjusting the scanning speed, the sampling frequency, the scanning stepping and the detection sensitivity of an automatic detection system, comprehensively scanning the comparison test block, respectively acquiring the ultrasonic signals of the first wave peak sound time, the first wave peak amplitude, the highest wave peak sound time, the highest wave peak amplitude, the tail wave peak sound time and the tail wave peak amplitude in the interval, respectively forming a C scanning image, and ensuring that the artificial defect of the initial evaluation size in the comparison test block can be detected by the initial system and clearly displayed in the generated 6C scanning images by adjusting the scanning speed, the sampling frequency, the scanning stepping and the detection sensitivity of the automatic detection system.
The reference block is a standard for judging the ultrasonic detection defects of the composite material part, is used for adjusting the detection sensitivity of an ultrasonic detection system and quantitatively evaluating the internal defects found in the part, represents the variation range of the material, the structure and the thickness of the part, and is preset with a plurality of artificial defects with different initial evaluation sizes at different depths and is used for determining specific parameters during automatic detection of the part. And the TCG curve is set, the amplitude of the bottom wave at different time domain positions is adjusted to the same height in a gain compensation mode, the bottom wave attenuation caused by the thickness change of the part is eliminated, and the accuracy of defect judgment is ensured.
And step three, carrying out integral scanning from one side of the part by adopting the detection parameters determined during scanning of the reference block in the step two to form 6C scanning images of head wave crest sound time, head wave crest amplitude, highest wave crest sound time, highest wave crest amplitude, tail wave crest sound time and tail wave crest amplitude. For the plate bonding structure area of the laminate part and the sandwich structure area of the sandwich part, the transducer needs to be arranged on the other side of the part, and scanning is performed again by adopting the same detection parameters to obtain another 6C scanning images for supplementing and monitoring defects such as inclusion, air holes, resin enrichment and the like in the lower plate of the plate bonding structure and defects of the skin inside and the plate core bonding interface on the other side of the sandwich structure.
Marking a defect indication part which is displayed in the 'wake wave crest sound time' image and is different from the theoretical thickness of the skin on one side of the part laminated structure/plate bonding structure or the honeycomb/foam bonding structure as a position A; marking a defect indication part which is displayed in the image during the sound wave crest of the first wave and is different from the theoretical thickness of the skin on one side of the upper plate or the honeycomb/foam bonding structure in the integral/plate-plate bonding structure of the laminated structure as a position B; and marking the defect indication part which is displayed in the 'tail wave crest amplitude' image and is different from the integral average amplitude gray level as a position C.
And step five, if the part A shows that the laminated structure or the honeycomb/foam sandwich structure is displayed, and is marked as A1, the same positions corresponding to the image with the highest peak sound time and the image with the highest peak amplitude value are marked as D1 and E1, at the moment, the amplitude value at the part E1 is larger than or equal to the amplitude value of the artificial defect in the same or similar ladder in the comparison test block, if the amplitude value at the part E1 is uniform, the sound time value at the part D1 is the same, and the A1, the E1 and the D1 have clear and regular boundary profiles, the defect is judged to be included, if not, the layered defect is judged, the size of the defect of the part A1 is measured, wherein the sound time value of the part D1 is the depth of the defect.
If the display at A shows that the plate bonding structure is marked as A2, the same positions in the images at the time of the highest wave peak sound and the images at the time of the highest wave peak amplitude are marked as D2 and E2, and good areas of the same structure near the corresponding area of A2 in the images at the time of the first wave peak sound and the images at the time of the first wave peak amplitude are marked as B2 'and F2', and the sound time value and the amplitude value are extracted. If the sound values of D2 and B2 'are the same, the defect appears in the depth of the bonding interface, and at the moment, the amplitude of E2 is 3-6 dB or more higher than the amplitude of F2', and the debonding defect is judged; if the sound time of D2 is less than that of B2', the defect is positioned in an upper plate of a plate-plate bonding structure, the amplitude of the E2 position is more than or equal to that of the artificial defect in the same or similar step with the same thickness in a reference block, if the amplitude of the E2 position is uniform, the sound time value of the D2 position is the same, and the A2, the E2 and the D2 have clear and regular boundary contours, the defect is judged to be a mixed defect, otherwise, the defect is judged to be a layered defect; if the sound time of D2 is larger than that of B2', the defect is positioned in a lower plate of a plate-plate bonding structure, the amplitude of the E2 position is larger than or equal to that of the artificial defect in the same area in a reference block, if the amplitude of the E2 position is uniform, the sound time values of the D2 position are the same, and the A2, the E2 and the D2 have clear and regular boundary profiles, the defect is judged to be a mixed defect, otherwise, the defect is judged to be a layered defect, and the size of the A2 defect is measured.
Sixthly, the positions of the A1 and the A2 corresponding to the images in the 'first wave crest sound time' are marked as B1 and B2, except the B1 and the B2, in the display at the B position, if other display areas indicate that the bottom wave of the laminated structure/plate bonding structure or the glue film wave of the honeycomb/foam sandwich structure stably exists when the defects appear, the area is marked as B3; if there is no other display area except for B1 and B2 in the display at B, there is no B3 defect. If the defect boundary contour displayed at the position B3 is regular and clear and the sound values in the area are the same, judging that the defect is included; if the defects displayed at the B3 position are distributed in a dispersed manner, judging that the resin is enriched; if the defect shown at the position B3 is in a dot shape or a small-size circle shape, the defect is judged to be an air hole, and the size of the defect B3 is measured.
Seventhly, the positions of the A1, the A2 and the B3 corresponding to the 'tail wave crest amplitude' image are marked as C1, C2 and C3, the C part display is except for C1, C2 and C3, if other display areas indicate that a defect wave does not exist between the surface echo and the bottom wave when the defect appears, the area is marked as C4; comparing the amplitude of the good area of the same structure nearby in the 'tail wave crest amplitude' image with the amplitude of the C4, if the amplitude of the good area of the same structure nearby in the 'tail wave crest amplitude' image is 6dB or more lower than that of the former, judging whether the C4 is located in a transition area of part thickness change, if so, displaying non-defect, otherwise, judging that the part has dense pores, and measuring the defect size of the C4; if the amplitude of the C4 position in the tail wave crest amplitude image is higher than that of the good area of the same structure nearby by more than 4dB and the C4 position shows that the honeycomb/foam sandwich structure exists, the C4 position is a plate core debonding defect, and the size of the defect of the C4 position is measured; if the relationship between the amplitude of the C4 position in the 'tail wave peak amplitude' image and the amplitude of the nearby good region with the same structure does not satisfy the two conditions, the C4 position is displayed in a non-defect mode.
And step eight, when the type of the inclusion defects at the positions A1, A2 and B3 needs to be judged, marking the positions of the areas A1, A2 and B3 corresponding to the head wave crest amplitude image as F1, F2 and F3, and calculating the sound pressure reflectivity of the inclusions according to the amplitudes at the positions F1, F2 and F3 so as to judge the type of the inclusions by contrasting the defect library.
And step nine, judging whether the part is qualified or not by combining the sizes of the defects displayed at the positions A1, A2, B3 and C4 and contrasting rejection indexes of the part.
The invention has the beneficial effects that:
the effective analysis interval definition mode and the defect multi-view imaging intelligent identification method based on the analysis interval have the advantages that:
1. for parts with complex structures and variable thicknesses, the gate acquisition signals of the maximum effective analysis interval defined by the invention are set, so that the overall thickness and structural changes of the parts can be intuitively reflected; for the laminate parts with gradually changed thicknesses, ultrasonic signals in the thickness transition area can be comprehensively collected and imaged, and the risk of missing detection and judgment is avoided.
2. The automatic scanning acquisition of the ultrasonic signals and the multi-view intelligent identification of the defects can effectively eliminate the influence of human factors on the detection accuracy, so that the detection result is more reliable.
3. The gate setting method based on the maximum effective interval is simple, convenient and quick to operate, does not need to manually adjust the width of the gate according to the positions of structural echoes such as film waves, bottom waves and the like, carries out complicated and tedious post-processing analysis, judges the defects through a multi-view defect imaging intelligent identification method, can save the time of manual analysis, and effectively improves the detection efficiency.
4. The method for intelligently identifying the defect multi-view imaging of the effective analysis interval is suitable for parts with complex structures and various thickness changes, wherein the parts have sudden and gradual changes in thickness, have stronger universality and more convenient and fast operation, and are more suitable for engineering application of automatic ultrasonic detection of composite materials.
Drawings
FIG. 1 is a schematic diagram of an effective analysis interval.
Fig. 2 is a schematic view of an imaging mode.
In the figure: 1, surface echo; 2, notching; 3 structural echo; 4, bottom wave; 5, a gate a;6, a gate b; a gate c;8, first wave crest; 9 highest peak; 10 tail wave peaks.
Detailed Description
The present invention is further illustrated by the following specific examples.
Examples
The structural form of a composite material part is a curvature variable thickness laminated structure and a double-layer variable thickness plate bonding structure of a skin and a partition plate. The whole thickness range of the part is 2-10.75 mm, the thickness of a reference block for the part is 2-11 mm, each 1mm is provided with a thickness step, the total thickness steps are 10, and artificial defects of initial evaluation sizes of different depths are pre-embedded in each step of the reference block.
The method is characterized in that the defect intelligent identification and evaluation method of ultrasonic automatic detection of the composite material is used for detection, and the following implementation steps are adopted:
firstly, determining an effective analysis interval, placing the transducer at the position of the area with the maximum overall thickness of the composite material part before the detection starts, namely scanning the area with the thickness of 10.75mm, and determining the time domain range from the surface echo 1 to the bottom wave 4 in the corresponding ultrasonic wave A oscillogram at the moment as the effective analysis interval of the defect, as shown in fig. 2.
Setting detection parameters of an automatic reflection method ultrasonic detection system, adjusting the angle of a transducer to enable the incident axis of ultrasonic waves to be vertical to the surface of a comparison test block, drawing a TCG (time correction gain) curve of the system according to the amplitude height of bottom waves of 10 thickness steps in the comparison test block, arranging 3 gates in an effective analysis interval, setting the initial position, the width and the height of the gate and a signal acquisition mode of the gate, adjusting the scanning speed, the sampling frequency, the scanning stepping, the detection sensitivity and other parameters of the automatic detection system to comprehensively scan the comparison test block, respectively acquiring ultrasonic signals of 'head wave crest sound time', 'head wave crest amplitude', 'highest crest sound time', 'highest crest amplitude', 'tail wave crest sound time', 'tail wave crest amplitude', respectively forming a C scanning image, and ensuring that the artificial defects of the initial size in the comparison test block can be detected and displayed clearly in the C scanning image of the system by adjusting the initial position, the width, the height and the signal acquisition mode of the gate.
And step three, adopting the setting of the detection parameters and the valve determined in the step two to carry out integral scanning on one side of the composite material part to form 6C scanning images of head wave crest sound time, head wave crest amplitude, highest wave crest sound time, highest wave crest amplitude, tail wave crest sound time and tail wave crest amplitude. For the area of the panel bonded structure, the transducer was placed on the other side of the area, and the same detection parameters were used to scan again, generating another 6C-scan images, for a total of 12.
Marking a defect indication part which is displayed in the 'wake wave crest sound time' image and is different from the theoretical thickness of the whole composite material part laminated plate/plate bonding structure as a position A; marking a defect indication part which is displayed in the image of the 'first wave crest sound time' and is different from the theoretical thickness of an upper plate in the laminate/plate bonding structure as a position B; marking the defect indication part which is displayed in the 'tail wave crest amplitude' image and is different from the integral average amplitude gray level as a position C;
and step five, displaying 2 positions of the position A, displaying 1 position in the laminated structure, marking as A1, and displaying 1 position in the plate bonding structure, marking as A2. The position of A1 is corresponding to the same position of the image with the highest peak sound time and the image with the highest peak amplitude and is marked as D1 and E1, the amplitude of the E1 is compared with the amplitude of the artificial defect with the same thickness or similar steps in the comparison test block, the amplitude of the E1 is larger, the sound time values of all points at the D1 have slight difference, the A1 is similar to an ellipse, the boundary is fuzzy and the contour is irregular, so the layered defect is judged; the positions of A2 are marked as D2 and E2 at the same positions in the image corresponding to the "time of peak sound" and the image corresponding to the "highest peak amplitude", and good areas of the same structure in the vicinity of the corresponding areas in the image corresponding to the "time of peak sound" and the image corresponding to the "first wave peak amplitude" are marked as B2 'and F2', and the sound values and amplitude values thereof are extracted. Comparing the sound values of D2 and B2 'with the same value shows that the defect occurs at the depth of the bonding interface, and the amplitude of E2 is 6dB higher than that of F2', so that the debonding defect is judged. The dimensions of A1 and A2 were measured to be 10 mm. Times.15 mm and 3 mm. Times.12 mm, respectively.
And sixthly, marking the positions of the A1 and the A2 corresponding to the head wave crest sound time in the image as B1 and B2, displaying that 1 small-size point-like defect (marked as B3) exists except the B1 and the B2 at the position B, judging that the defect is an air hole, and ensuring that the size of the defect is about 1mm multiplied by 2mm.
And seventhly, marking the positions of the A1, the A2 and the B3 corresponding to the 'wake wave crest amplitude' image as C1, C2 and C3, displaying that 2 display areas exist except the C1, the C2 and the C3 at the C, marking as C4 and C5, comparing the amplitudes of the areas with good structure and the areas C4 and C5 in the 'wake wave crest amplitude' image, wherein the amplitude of the area C4 is 8.2dB lower than that of the area with good structure, and the amplitude of the area C5 is 4.5dB lower than that of the area with good structure, so that the C4 is a pore dense defect, and the C5 is a non-defect display. The dimensions of C4 were measured to be 6mm by 4mm.
Step eight, no display except the corresponding positions of A1, A2, B3, C4 and C5 exists in 6C scanning images of the board bonding structure area scanned from the other side, so that no defect exists in the board bonding structure lower board.
Step nine, comparing the rejection indexes of the part, judging that the delamination and debonding defects exceed the acceptance criteria, and judging that the part is unqualified because other defects are within the design allowable requirement range.
The above-mentioned embodiments only express the embodiments of the present invention, but not should be understood as the limitation of the scope of the invention patent, it should be noted that, for those skilled in the art, many variations and modifications can be made without departing from the concept of the present invention, and these all fall into the protection scope of the present invention.
Claims (3)
1. An intelligent defect identification and evaluation method for ultrasonic automatic detection of composite materials is characterized by comprising the following steps:
step one, determining an effective analysis interval;
step two, setting detection parameters and a signal acquisition gate of the automatic reflection method ultrasonic detection system;
step three, adopting the detection parameters determined during scanning of the reference block in the step two, and performing overall scanning from one side of the part to form 6C scanning images of head wave crest sound time, head wave crest amplitude, highest wave crest sound time, highest wave crest amplitude, tail wave crest sound time and tail wave crest amplitude; for the plate bonding structure area of the laminate part and the sandwich structure area of the interlayer part, the transducer needs to be arranged on the other side of the part, and scanning is carried out again by adopting the same detection parameters to obtain another 6C scanning images;
marking a defect indication; marking a defect indication part which is displayed in the image during the sound wave crest of the tail wave and has different theoretical thicknesses with the whole part laminated structure/plate bonding structure or one side skin of the honeycomb/foam bonding structure as a position A; marking a defect indication part which is displayed in the image during the sound wave crest of the first wave and is different from the theoretical thickness of the skin on one side of the upper plate or the honeycomb/foam bonding structure in the integral laminated structure/plate-plate bonding structure as a position B; marking the defect indication part which is displayed in the 'tail wave crest amplitude' image and is different from the integral average amplitude gray scale as a position C;
step five, if the part A shows that the laminated structure or the honeycomb/foam sandwich structure is present and is marked as A1, the same positions in the image of the highest peak sound time and the image of the highest peak amplitude value are marked as D1 and E1, at the moment, the amplitude value of the part E1 is larger than or equal to the amplitude value of the artificial defect in the same or similar ladder in the reference block, if the amplitude value of the part E1 is uniform, the sound time value of the part D1 is the same, and the parts A1, E1 and D1 have clear and regular boundary profiles, the defect is judged to be included, otherwise, the defect is judged to be layered, the size of the defect A1 is measured, wherein the sound time value of the part D1 is the depth of the defect;
if the plate bonding structure mark A2 shows that the plate bonding structure mark is A2, the same positions in the image with the highest peak sound time and the image with the highest peak amplitude are marked as D2 and E2, and good areas of the same structure near the area corresponding to the A2 in the image with the first wave peak sound time and the image with the first wave peak amplitude are marked as B2 'and F2', and the sound time value and the amplitude value are extracted; if the sound values of D2 and B2 'are the same, the defect appears in the depth of the bonding interface, and at the moment, the amplitude of E2 is 3-6 dB or more higher than the amplitude of F2', and the debonding defect is judged; if the sound time of D2 is less than that of B2', the defect is positioned in an upper plate of a plate-plate bonding structure, the amplitude of the E2 position is more than or equal to that of the artificial defect in the same or similar step with the same thickness in a reference block, if the amplitude of the E2 position is uniform, the sound time value of the D2 position is the same, and the A2, the E2 and the D2 have clear and regular boundary contours, the defect is judged to be a mixed defect, otherwise, the defect is judged to be a layered defect; if the sound time of D2 is larger than that of B2', the defect is positioned in a lower plate of a plate-plate bonding structure, the amplitude of the E2 position is larger than or equal to that of the artificial defect in the same area in a reference block, if the amplitude of the E2 position is uniform, the sound time values of the D2 position are the same, and the A2, the E2 and the D2 have clear and regular boundary profiles, the defect is judged to be a mixed defect, otherwise, the defect is judged to be a layered defect, and the size of the A2 defect is measured;
sixthly, the positions of the A1 and the A2 corresponding to the images in the 'first wave crest sound time' are marked as B1 and B2, and the area B is marked as B3 except the B1 and the B2 in the display, if other display areas indicate that the bottom wave of the laminated structure/plate bonding structure or the glue film wave of the honeycomb/foam sandwich structure stably exists when the defects appear; b3 defects do not exist except B1 and B2 in the display at the position B if other display areas do not exist; if the defect boundary contour displayed at the position B3 is regular and clear and the sound values in the region are the same, judging that the defect is included; if the defects displayed at the B3 position are distributed in a dispersed manner, judging that the resin is enriched; if the defect displayed at the position B3 is in a point shape or a small-size circle shape, judging the defect as an air hole; measuring the size of the B3 defect;
seventhly, marking the positions of the A1, the A2 and the B3 corresponding to the images of the 'tail wave crest amplitude value' as C1, C2 and C3, wherein the positions of the C are displayed except for the C1, the C2 and the C3, and if other display areas exist, marking the area as C4; comparing the amplitude of the good area of the same structure and the amplitude of the C4 position nearby in the 'tail wave crest amplitude' image, if the amplitude of the tail wave crest amplitude 'image is lower than the amplitude of the good area of the same structure by 6dB or more than the amplitude of the tail wave crest amplitude', judging whether the C4 position is located in a transition area with the changed thickness of the part, if so, displaying non-defects, otherwise, judging that the defect is dense in pores, and measuring the size of the defect of the C4; if the amplitude of the C4 position in the tail wave crest amplitude image is higher than that of the good area of the same structure nearby by more than 4dB and the C4 position shows that the honeycomb/foam sandwich structure exists, the C4 position is a plate core debonding defect, and the size of the defect of the C4 position is measured; if the relationship between the amplitude of the C4 position in the 'tail wave crest amplitude' image and the amplitude of the nearby good region with the same structure does not satisfy the two conditions, displaying the C4 position in a non-defect mode;
step eight, when the type of inclusion defects at the positions A1, A2 and B3 needs to be judged, marking the positions of the areas A1, A2 and B3 corresponding to the head wave crest amplitude image as F1, F2 and F3, and calculating the sound pressure reflectivity of the inclusions according to the amplitudes at the positions F1, F2 and F3 so as to judge the type of the inclusions by contrasting the defect library;
and step nine, judging whether the part is qualified or not by combining the sizes of the defects displayed at the positions A1, A2, B3 and C4 and contrasting rejection indexes of the part.
2. The method for intelligently identifying and evaluating the defects of the ultrasonic automated detection of the composite material according to claim 1, wherein the determination process of the effective analysis interval in the first step is specifically as follows: before the detection starts, the transducer is placed at the position of an area with the largest integral thickness of the part to be scanned, the time domain position of a bottom wave (4) in an ultrasonic A scanning waveform is observed, and the time domain range from the surface echo (1) to the position behind the bottom wave (4) is an effective analysis interval for judging the part defects.
3. The intelligent defect identification and evaluation method for ultrasonic automatic detection of composite materials according to claim 1, wherein in the second step, the setting process of detecting parameters and signal acquisition gates of the automatic reflection method ultrasonic detection system is as follows:
adjusting the angle of a transducer to ensure that the incident axis of ultrasonic waves is vertical to the surface of a reference test block, setting a time correction gain curve according to the amplitude heights of bottom waves of a plurality of thickness ladders in the reference test block, setting 3 gates in an effective analysis interval, setting the initial positions, the gate widths, the gate heights and the signal acquisition modes of the gates, adjusting the scanning speed, the sampling frequency, the scanning stepping and the detection sensitivity of an automatic detection system, comprehensively scanning the reference test block, respectively acquiring ultrasonic signals of 'first wave peak sound time', 'first wave peak amplitude', 'highest peak sound time', 'highest peak amplitude', 'tail wave peak sound time' and 'tail wave peak amplitude' in the interval, respectively forming C scanning images, and ensuring that artificial defects of initial evaluation sizes in the reference test block can be detected by the system and clearly displayed in the generated 6C scanning images by adjusting the scanning speed, the sampling frequency, the scanning stepping, the detection sensitivity, the initial positions of the gates, the gate widths, the gate heights and the signal acquisition modes of the gates, thereby determining detection parameters;
the method comprises the following steps that a plurality of artificial defects with initial evaluation sizes at different depths are preset in a reference block and are used for determining specific parameters during automatic detection of the part and quantitatively evaluating internal defects found in the part; the TCG curve is set for eliminating bottom wave attenuation caused by part thickness change, and accuracy of defect judgment is guaranteed.
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| CN117147695B (en) * | 2023-09-04 | 2024-05-17 | 东莞乐嘉塑胶制品有限公司 | Defect detection method and system for plastic mold |
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