CN108072700A - A kind of steel ball ultrasonic detection method and device based on point focusing probe - Google Patents
A kind of steel ball ultrasonic detection method and device based on point focusing probe Download PDFInfo
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 160
- 239000010959 steel Substances 0.000 title claims abstract description 160
- 239000000523 sample Substances 0.000 title claims abstract description 147
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- 230000007547 defect Effects 0.000 claims abstract description 84
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 32
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- G—PHYSICS
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Abstract
本发明公开一种基于点聚焦探头的钢球超声探伤方法与装置,该方法包括:根据点聚焦探头在待检测钢球球体内的实际焦距及折射定律,结合待检测钢球的直径规格,选择点聚焦探头的型号、水层厚度及点聚焦探头声源轴线与待检测钢球球心的偏心距;超声仪产生高频脉冲信号,激励点聚焦探头产生超声波,超声波经耦合介质水进入待检测钢球内进行缺陷检测;待检测钢球在点聚焦探头的有效检测区域范围内进行球面全展开,点聚焦探头接收超声回波信号,根据超声回波信号判断待检测钢球是否存在缺陷。本发明结构简单,操作方便,使用安全,通用性强,成本低,检测精度高,易于实现钢球的自动化探伤,对保证钢球质量,提高轴承可靠性等具有重要意义。
The invention discloses a steel ball ultrasonic flaw detection method and device based on a point focusing probe. The method includes: according to the actual focal length and refraction law of the point focusing probe in the steel ball to be detected, combined with the diameter specification of the steel ball to be detected, select The model of the point-focusing probe, the thickness of the water layer and the eccentric distance between the axis of the sound source of the point-focusing probe and the center of the steel ball to be detected; the ultrasonic instrument generates a high-frequency pulse signal, which excites the point-focusing probe to generate ultrasonic waves, and the ultrasonic waves pass through the coupling medium water to be detected Defect detection is carried out in the steel ball; the steel ball to be tested is fully expanded spherically within the effective detection area of the point focusing probe, and the point focusing probe receives the ultrasonic echo signal, and judges whether the steel ball to be tested has a defect according to the ultrasonic echo signal. The invention is simple in structure, convenient in operation, safe in use, strong in versatility, low in cost, high in detection accuracy, easy to realize automatic flaw detection of steel balls, and has great significance for ensuring the quality of steel balls and improving the reliability of bearings.
Description
技术领域technical field
本发明涉及超声检测技术与钢球无损探伤技术领域,尤其涉及一种基于点聚焦探头的钢球超声探伤方法与装置。The invention relates to the fields of ultrasonic detection technology and steel ball non-destructive flaw detection technology, in particular to a steel ball ultrasonic flaw detection method and device based on a point focusing probe.
背景技术Background technique
作为机械工业核心基础的零部件,轴承被广泛应用于国民经济的各行各业中,而球轴承在所有种类轴承中应用最为广泛。钢球作为球轴承的关键零件,它的质量对球轴承的精度、传动性能和使用寿命有着重要影响。当钢球处于高速重载条件下工作时,它表面或者内部如果存在微小的气孔或裂纹等质量问题极易致使缺陷长大、延伸,最终导致轴承失效,严重者将会造成重大安全事故,危害生命健康以及财产安全。As the core components of the machinery industry, bearings are widely used in all walks of life in the national economy, and ball bearings are the most widely used in all types of bearings. As the key part of the ball bearing, the quality of the steel ball has an important impact on the accuracy, transmission performance and service life of the ball bearing. When the steel ball is working under high-speed and heavy-load conditions, if there are quality problems such as tiny pores or cracks on the surface or inside, it is easy to cause the defects to grow and extend, and eventually lead to bearing failure. In severe cases, it will cause major safety accidents and endanger life and health and property safety.
目前国内绝大数企业仍然采用的是人工检测法进行钢球质量缺陷检测。这种检测方法不仅需要投入大量的劳动力,效率极低,而且检测质量受工人的情绪、责任心以及技术水平等影响很大,很容易造成误检和漏检,影响企业的产品质量和生产效益,此外,工人长时间在强光源的条件下工作极容易对眼睛造成伤害。虽然国内外的许多专家学者已经成功应用机器视觉法、光电检测法以及涡流检测法对钢球进行缺陷检测,但是这些技术只能检测出钢球表面及近表面的缺陷,对于钢球存在的气孔、夹杂等内部缺陷无能为力。At present, the vast majority of domestic enterprises still use the manual detection method to detect steel ball quality defects. This detection method not only requires a large amount of labor, but the efficiency is extremely low, and the detection quality is greatly affected by the workers' emotions, sense of responsibility and technical level, which can easily cause false detection and missed detection, and affect the product quality and production efficiency of the enterprise. , In addition, workers working under the condition of strong light source for a long time can easily cause damage to the eyes. Although many experts and scholars at home and abroad have successfully applied the machine vision method, photoelectric detection method and eddy current detection method to detect the defects of steel balls, these technologies can only detect the defects on the surface and near the surface of the steel balls, and the air holes in the steel balls , inclusions and other internal defects powerless.
发明内容Contents of the invention
本发明的目的在于通过一种基于点聚焦探头的钢球超声探伤方法与装置,来解决以上背景技术部分提到的问题。The object of the present invention is to solve the problems mentioned above in the background technology section through a steel ball ultrasonic flaw detection method and device based on a point focusing probe.
为达此目的,本发明采用以下技术方案:For reaching this purpose, the present invention adopts following technical scheme:
一种基于点聚焦探头的钢球超声探伤方法,其包括如下步骤:A steel ball ultrasonic flaw detection method based on a point-focused probe, comprising the steps of:
S101、根据点聚焦探头在待检测钢球球体内的实际焦距及折射定律,结合待检测钢球的直径规格,选择点聚焦探头的型号、水层厚度以及点聚焦探头声源轴线与待检测钢球球心的偏心距;S101. According to the actual focal length and refraction law of the point-focusing probe in the steel ball to be detected, combined with the diameter specifications of the steel ball to be detected, select the model of the point-focusing probe, the thickness of the water layer, and the axis of the sound source of the point-focusing probe and the steel ball to be detected. The eccentricity of the center of the ball;
S102、超声仪产生高频脉冲信号,激励点聚焦探头产生超声波,超声波经耦合介质水进入待检测钢球内进行缺陷检测;S102, the ultrasonic instrument generates a high-frequency pulse signal, the excitation point focusing probe generates ultrasonic waves, and the ultrasonic waves enter the steel ball to be detected through the coupling medium water for defect detection;
S103、待检测钢球在点聚焦探头的有效检测区域范围内进行球面全展开,点聚焦探头接收超声回波信号,根据所述超声回波信号判断所述待检测钢球是否存在缺陷。S103 , the steel ball to be detected is fully expanded spherically within the effective detection area of the point-focused probe, and the point-focused probe receives ultrasonic echo signals, and judges whether the steel ball to be detected has defects according to the ultrasonic echo signals.
特别地,所述步骤S101包括:调节点聚焦探头的位置,使其声源轴线与待检测钢球的球心共线,实现对待检测钢球的内部缺陷检测。In particular, the step S101 includes: adjusting the position of the point-focusing probe so that the axis of the sound source is collinear with the center of the steel ball to be detected, so as to realize the internal defect detection of the steel ball to be detected.
特别地,所述步骤S101包括:根据点聚焦探头发射的超声波在待检测钢球内实际焦距,选择点聚焦探头的型号和水层厚度,将点聚焦探头的实际聚焦区域调节至钢球底部,其中,所述点聚焦探头的型号包括晶片直径和焦距。In particular, the step S101 includes: according to the actual focal length of the ultrasonic waves emitted by the point-focus probe in the steel ball to be detected, select the model of the point-focus probe and the thickness of the water layer, and adjust the actual focus area of the point-focus probe to the bottom of the steel ball, Wherein, the model of the point focusing probe includes wafer diameter and focal length.
特别地,所述步骤S101包括:根据点聚焦探头发射的超声波在交质界面的折射定律及斯奈尔定律,调节点聚焦探头的位置,使其声源轴线偏离待检测钢球的球心达到设定距离,使进入待检测钢球内的超声波转换为横波,实现对待检测钢球的表面缺陷检测。In particular, the step S101 includes: adjusting the position of the point-focusing probe according to the refraction law and Snell's law of the ultrasonic waves emitted by the point-focusing probe at the interface between substances, so that the axis of the sound source deviates from the center of the steel ball to be detected to reach Set the distance so that the ultrasonic wave entering the steel ball to be detected is converted into a transverse wave, and the surface defect detection of the steel ball to be detected is realized.
特别地,用于待检测钢球表面缺陷检测的点聚焦探头与用于待检测钢球内部缺陷检测的点聚焦探头的型号相同,但与待检测钢球的设置的相对位置不同。In particular, the type of the point focusing probe used to detect the surface defect of the steel ball to be tested is the same as that used for the detection of the internal defect of the steel ball to be tested, but the relative position of the setting of the steel ball to be tested is different.
特别地,所述步骤S103具体包括:待检测钢球在点聚焦探头的有效检测区域范围内进行球面全展开,点聚焦探头接收超声回波信号并将其转换为电压信号输出给超声仪,超声仪对收到的电压信号进行包括放大、滤波、A/D转换在内的数据处理,提取出信号特征用波形图形的方式呈现在显示器上,根据所述波形图形判断所述待检测钢球是否存在缺陷。In particular, the step S103 specifically includes: the steel ball to be detected is fully expanded spherically within the effective detection area of the point focusing probe, the point focusing probe receives the ultrasonic echo signal and converts it into a voltage signal and outputs it to the ultrasonic instrument, and the ultrasonic The instrument performs data processing including amplification, filtering and A/D conversion on the received voltage signal, extracts the signal characteristics and presents them on the display in the form of waveform graphics, and judges whether the steel ball to be detected is Flawed.
本发明还公开了一种实现上述钢球超声探伤方法的钢球超声探伤装置,该装置包括:钢球展开机构、第一点聚焦探头、第二点聚焦探头、探头调节支架、水箱、超声仪以及显示器;所述钢球展开机构用于将待检测钢球的表面在第一点聚焦探头、第二点聚焦探头的有效检测区域范围内进行全展开;所述探头调节支架用于安装第一点聚焦探头、第二点聚焦探头,调节第一点聚焦探头、第二点聚焦探头与待检测钢球球心的相对位置;所述第一点聚焦探头、第二点聚焦探头与超声仪电连接,设置在所述水箱内;所述水箱内盛放耦合介质水;所述超声仪与显示器电连接,用于产生高频脉冲信号,激励第一点聚焦探头、第二点聚焦探头发射超声波,超声波通过耦合介质水进入待检测钢球进行缺陷检测,第一点聚焦探头、第二点聚焦探头接收超声回波信号并将其转换为电压信号输出给超声仪,超声仪对收到的电压信号进行包括放大、滤波、A/D转换在内的数据处理,提取出信号特征用波形图形的方式呈现在显示器上,根据所述波形图形判断所述待检测钢球是否存在缺陷。The invention also discloses a steel ball ultrasonic flaw detection device for realizing the above-mentioned steel ball ultrasonic flaw detection method. and a display; the steel ball unfolding mechanism is used to fully expand the surface of the steel ball to be detected within the effective detection area range of the first point focusing probe and the second point focusing probe; the probe adjustment bracket is used to install the first Point focusing probe, the second point focusing probe, adjust the relative position of the first point focusing probe, the second point focusing probe and the steel ball center to be detected; the first point focusing probe, the second point focusing probe and the electric Connected, set in the water tank; the water tank is filled with coupling medium water; the ultrasonic instrument is electrically connected with the display, used to generate high-frequency pulse signals, and excite the first point focusing probe and the second point focusing probe to emit ultrasonic waves , the ultrasonic wave enters the steel ball to be detected through the coupling medium water for defect detection. The first point focusing probe and the second point focusing probe receive the ultrasonic echo signal and convert it into a voltage signal and output it to the ultrasonic instrument. The signal undergoes data processing including amplification, filtering, and A/D conversion, and the extracted signal features are presented on the display in the form of waveform graphics, and it is judged according to the waveform graphics whether there is a defect in the steel ball to be detected.
本发明提出的基于点聚焦探头的钢球超声探伤方法与装置不仅可以检测钢球的表面缺陷,也能够检测钢球的内部缺陷,弥补现有技术对钢球的探伤盲点。本发明中通过分析点聚焦探头在钢球内实际焦距,选择点聚焦探头的参数与水层厚度,有效提高了超声波对钢球内部缺陷的灵敏度,并改善缺陷回波的信噪比。本发明能够对不同直径规格的钢球进行缺陷检测,通用性和互换性强。本发明提供的基于点聚焦探头的钢球超声探伤装置结构简单,操作方便,使用安全,通用性强,成本低,检测精度高,易于实现钢球的自动化探伤,对保证钢球质量,提高轴承可靠性等具有重要意义,适宜推广应用,具有广阔的市场应用前景。The steel ball ultrasonic flaw detection method and device based on the point focusing probe proposed by the present invention can not only detect the surface defect of the steel ball, but also detect the internal defect of the steel ball, and make up for the blind spot of the steel ball flaw detection in the prior art. In the present invention, by analyzing the actual focal length of the point-focusing probe in the steel ball and selecting the parameters of the point-focusing probe and the thickness of the water layer, the sensitivity of ultrasonic waves to internal defects of the steel ball is effectively improved, and the signal-to-noise ratio of defect echoes is improved. The invention can detect the defects of steel balls with different diameters and specifications, and has strong versatility and interchangeability. The steel ball ultrasonic flaw detection device based on the point focusing probe provided by the present invention is simple in structure, easy to operate, safe to use, strong in versatility, low in cost, high in detection accuracy, and easy to realize automatic flaw detection of steel balls, which is very important for ensuring the quality of steel balls and improving the quality of bearings. Reliability, etc. are of great significance, suitable for popularization and application, and have broad market application prospects.
附图说明Description of drawings
图1为本发明提供的基于点聚焦探头的钢球超声探伤装置结构示意图;Fig. 1 is a structural schematic diagram of a steel ball ultrasonic flaw detection device based on a point focusing probe provided by the present invention;
图2为本发明提供的点聚焦探头检测钢球内部缺陷的原理示意图;Fig. 2 is the schematic diagram of the principle of detecting the internal defect of the steel ball by the point focusing probe provided by the present invention;
图3为本发明提供的点聚焦探头发射的超声波在钢球内传播路径及聚焦情况的示意图;Fig. 3 is the schematic diagram of the transmission path and focusing situation of the ultrasonic waves emitted by the point focusing probe provided by the present invention in the steel ball;
图4A为本发明提供的钢球平底孔缺陷示意图;图4B至图4F为本发明提供的不同深度的钢球平底孔缺陷的回波信号示意图;Fig. 4A is a schematic diagram of steel ball flat-bottomed hole defects provided by the present invention; Fig. 4B to Fig. 4F are schematic diagrams of echo signals of steel ball flat-bottomed hole defects of different depths provided by the present invention;
图5为本发明提供的超声折射定律的原理示意图;Fig. 5 is the schematic diagram of the principle of the law of ultrasonic refraction provided by the present invention;
图6A1至图6A8为本发明提供的钢球各类表面缺陷的回波信号示意图。6A1 to 6A8 are schematic diagrams of echo signals of various surface defects of steel balls provided by the present invention.
具体实施方式Detailed ways
为了便于理解本发明,下面将参照相关附图对本发明进行更全面的描述。附图中给出了本发明的较佳实施例。但是,本发明可以以许多不同的形式来实现,并不限于本文所描述的实施例。相反地,提供这些实施例的目的是使对本发明的公开内容理解的更加透彻全面。需要说明的是,当一个元件被认为是“连接”另一个元件,它可以是直接连接到另一个元件或者可能同时存在居中元件。除非另有定义,本文所使用的所有的技术和科学术语与属于本发明的技术领域的技术人员通常理解的含义相同。本文中在本发明的说明书中所使用的术语只是为了描述具体的实施例的目的,不是旨在于限制本发明。本文所使用的术语“及/或”包括一个或多个相关的所列项目的任意的和所有的组合。In order to facilitate the understanding of the present invention, the present invention will be described more fully below with reference to the associated drawings. Preferred embodiments of the invention are shown in the accompanying drawings. However, the present invention can be embodied in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more thorough and comprehensive. It should be noted that when an element is considered to be "connected" to another element, it may be directly connected to the other element or there may be intervening elements at the same time. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the technical field of the invention. The terms used herein in the description of the present invention are for the purpose of describing specific embodiments only, and are not intended to limit the present invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
请参照图1所示,图1为本发明提供的基于点聚焦探头的钢球超声探伤装置结构示意图。Please refer to FIG. 1 , which is a structural schematic diagram of a steel ball ultrasonic flaw detection device based on a point focusing probe provided by the present invention.
本实施例中基于点聚焦探头的钢球超声探伤装置具体包括:钢球展开机构2、第一点聚焦探头3、第二点聚焦探头3’、探头调节支架4、水箱5、超声仪6以及显示器7。所述钢球展开机构2用于将待检测钢球1的表面在第一点聚焦探头3、第二点聚焦探头3’的有效检测区域范围内进行全展开。所述探头调节支架4用于安装第一点聚焦探头3、第二点聚焦探头3’,调节第一点聚焦探头3、第二点聚焦探头3’与待检测钢球1球心的相对位置。所述第一点聚焦探头3、第二点聚焦探头3’与超声仪6电连接,设置在所述水箱5内。所述水箱5内盛放耦合介质水8。所述超声仪6与显示器7电连接,用于产生高频脉冲信号,激励第一点聚焦探头3、第二点聚焦探头3’发射超声波,超声波通过耦合介质水8进入待检测钢球1进行缺陷检测,第一点聚焦探头3、第二点聚焦探头3’接收超声回波信号并将其转换为电压信号输出给超声仪6,超声仪6对收到的电压信号进行包括放大、滤波、A/D转换在内的数据处理,提取出信号特征用波形图形的方式呈现在显示器7上,根据所述波形图形判断所述待检测钢球1是否存在缺陷。In this embodiment, the steel ball ultrasonic flaw detection device based on the point focusing probe specifically includes: a steel ball expansion mechanism 2, a first point focusing probe 3, a second point focusing probe 3', a probe adjustment bracket 4, a water tank 5, an ultrasonic instrument 6 and monitor7. The steel ball unfolding mechanism 2 is used to fully expand the surface of the steel ball 1 to be detected within the effective detection area range of the first point focusing probe 3 and the second point focusing probe 3'. The probe adjustment bracket 4 is used to install the first point focusing probe 3 and the second point focusing probe 3', and adjust the relative position of the first point focusing probe 3, the second point focusing probe 3' and the center of the steel ball 1 to be detected . The first point-focusing probe 3 and the second point-focusing probe 3' are electrically connected to the ultrasonic instrument 6, and are arranged in the water tank 5. The coupling medium water 8 is contained in the water tank 5 . The ultrasonic instrument 6 is electrically connected with the display 7, and is used to generate a high-frequency pulse signal to excite the first point focusing probe 3 and the second point focusing probe 3' to emit ultrasonic waves, and the ultrasonic waves enter the steel ball 1 to be detected through the coupling medium water 8 for further processing. Defect detection, the first point focusing probe 3 and the second point focusing probe 3' receive the ultrasonic echo signal and convert it into a voltage signal and output it to the ultrasonic instrument 6, and the ultrasonic instrument 6 includes amplification, filtering, Data processing including A/D conversion extracts signal features and presents them on the display 7 in the form of waveform graphics, and judges whether the steel ball 1 to be detected has defects according to the waveform graphics.
基于上述实施钢球超声探伤的装置,本实施例公开了一种基于点聚焦探头的钢球超声探伤方法,该方法包括如下步骤:Based on the above-mentioned device for implementing ultrasonic flaw detection of steel balls, this embodiment discloses a method for ultrasonic flaw detection of steel balls based on a point-focused probe. The method includes the following steps:
S101、根据点聚焦探头(3,3’)在待检测钢球1球体内的实际焦距及折射定律,结合待检测钢球1的直径规格,选择点聚焦探头(3,3’)的型号、水层厚度以及点聚焦探头(3,3’)声源轴线与待检测钢球1球心的偏心距。S101. According to the actual focal length and refraction law of the point focusing probe (3, 3') inside the steel ball 1 to be detected, and in combination with the diameter specification of the steel ball 1 to be detected, select the model of the point focusing probe (3, 3'), The thickness of the water layer and the eccentric distance between the axis of the sound source of the point focusing probe (3, 3') and the center of the steel ball 1 to be detected.
S102、超声仪6产生高频脉冲信号,激励点聚焦探头(3,3’)产生超声波,超声波经耦合介质水8进入待检测钢球1内进行缺陷检测。S102, the ultrasonic instrument 6 generates a high-frequency pulse signal, and the point-focusing probe (3, 3') is excited to generate ultrasonic waves, and the ultrasonic waves enter the steel ball 1 to be detected through the coupling medium water 8 for defect detection.
S103、待检测钢球1在点聚焦探头(3,3’)的有效检测区域范围内进行球面全展开,点聚焦探头(3,3’)接收超声回波信号,根据所述超声回波信号判断所述待检测钢球1是否存在缺陷。在本实施例中点聚焦探头(3,3’)接收超声回波信号并将其转换为电压信号输出给超声仪6,超声仪6对收到的电压信号进行包括放大、滤波、A/D转换在内的数据处理,提取出信号特征用波形图形的方式呈现在显示器7上,根据所述波形图形判断所述待检测钢球1是否存在缺陷。S103, the steel ball 1 to be detected is fully expanded spherically within the effective detection area of the point focusing probe (3, 3'), and the point focusing probe (3, 3') receives the ultrasonic echo signal, according to the ultrasonic echo signal It is judged whether there is a defect in the steel ball 1 to be detected. In this embodiment, the point focus probe (3, 3') receives the ultrasonic echo signal and converts it into a voltage signal and outputs it to the ultrasonic instrument 6, and the ultrasonic instrument 6 includes amplification, filtering, and A/D for the received voltage signal. The data processing including the conversion extracts the signal features and presents them on the display 7 in the form of waveform graphics, and judges whether the steel ball 1 to be detected has defects according to the waveform graphics.
具体的,在检测所示待检测钢球1内部缺陷时,调节第一点聚焦探头3的位置,使其声源轴线与待检测钢球1的球心共线,实现对待检测钢球1的内部缺陷检测。如图2所示,图2为本发明提供的点聚焦探头检测钢球内部缺陷的原理示意图。结合声源轴线上的声压分布公式:Specifically, when detecting the internal defects of the steel ball 1 to be detected, the position of the first point focusing probe 3 is adjusted so that the axis of the sound source is collinear with the center of the steel ball 1 to be detected, and the accuracy of the steel ball 1 to be detected is realized. Internal defect detection. As shown in FIG. 2 , FIG. 2 is a schematic diagram of the principle of detecting internal defects of a steel ball by a point focusing probe provided by the present invention. Combined with the sound pressure distribution formula on the axis of the sound source:
P=2P0sin[π/2*B(1-X/F)]/(1-X/F)P=2P 0 sin[π/2*B(1-X/F)]/(1-X/F)
其中,P0指声源的初始声压;F指焦距;X指测量点至声源轴线的距离;B指与焦点尖锐度有关的参数。可以得知:调节第一点聚焦探头3的位置,使其声源轴线与待检测钢球1的球心共线,当待检测钢球1的内部缺陷9处于第一点聚焦探头3的声源轴线上时,可在待检测钢球1的底波信号前找到表征缺陷9的回波信号。本领域的技术人员容易理解:在第一点聚焦探头3的聚焦区范围内,检测灵敏度和信噪比均明显高于非聚焦探头,但在聚焦区范围外,检测灵敏度下降很快,检测效果甚至可能不如非聚焦探头。因此,分析第一点聚焦探头3在待检测钢球1内的实际焦距,找出实际聚焦区域是十分必要的。Among them, P 0 refers to the initial sound pressure of the sound source; F refers to the focal length; X refers to the distance from the measurement point to the axis of the sound source; B refers to the parameters related to the sharpness of the focus. It can be known that the position of the first point focusing probe 3 is adjusted so that the axis of the sound source is collinear with the center of the steel ball 1 to be detected. When the source is on the axis, the echo signal representing the defect 9 can be found before the bottom wave signal of the steel ball 1 to be detected. It is easy for those skilled in the art to understand: within the focus area of the first point focus probe 3, the detection sensitivity and signal-to-noise ratio are significantly higher than those of the non-focus probe, but outside the focus area, the detection sensitivity drops rapidly, and the detection effect Possibly even inferior to unfocused probes. Therefore, it is very necessary to analyze the actual focal length of the first point focusing probe 3 in the steel ball 1 to be tested to find out the actual focusing area.
根据第一点聚焦探头3发射的超声波在待检测钢球1内实际焦距,选择第一点聚焦探头3的型号和水层厚度,将第一点聚焦探头3的实际聚焦区域调节至钢球底部,从而提高超声波对钢球内部缺陷的灵敏度,并改善缺陷回波的信噪比。其中,所述第一点聚焦探头3的型号包括晶片直径和焦距。如图3所示,图3为本发明提供的点聚焦探头发射的超声波在钢球内传播路径及聚焦情况的示意图,图中F’为第一点聚焦探头3在钢球内的实际焦点,F为第一点聚焦探头3的焦点,a表示水层厚度,b表示实际焦点F’距钢球表面的距离,c表示实际焦点F’与焦点F之间的距离,d表示焦点F距钢球球心的距离,f表示焦距,f’表示实际焦距,R为钢球的曲率半径,D表示第一点聚焦探头3晶片的直径大小。According to the actual focal length of the ultrasonic waves emitted by the first point focusing probe 3 in the steel ball 1 to be tested, select the model of the first point focusing probe 3 and the thickness of the water layer, and adjust the actual focus area of the first point focusing probe 3 to the bottom of the steel ball , so as to improve the sensitivity of ultrasonic waves to internal defects of steel balls and improve the signal-to-noise ratio of defect echoes. Wherein, the model of the first point focusing probe 3 includes the wafer diameter and focal length. As shown in Figure 3, Figure 3 is a schematic diagram of the propagation path and focusing situation in the steel ball of the ultrasonic waves emitted by the point-focusing probe provided by the present invention, and F' is the actual focus of the first point-focusing probe 3 in the steel ball among the figures, F is the focal point of the first point focusing probe 3, a represents the thickness of the water layer, b represents the distance between the actual focal point F' and the steel ball surface, c represents the distance between the actual focal point F' and the focal point F, and d represents the distance between the focal point F' and the steel ball The distance between the center of the sphere, f represents the focal length, f' represents the actual focal length, R is the radius of curvature of the steel ball, and D represents the diameter of the first point focusing probe 3 chip.
结合超声的折射定律分析可以得到实际焦距的表达公式:Combined with the analysis of ultrasonic refraction law, the expression formula of the actual focal length can be obtained:
f'=f+dk/[(dC工/RC耦)sin2γ-k],式中f'=f+dk/[(dC work /RC coupling ) sin 2 γ-k], where
d=f-a-R,sinγ=D/2f。d=f-a-R, sinγ=D/2f.
此可以根据上述实际焦距f’的表达公式选择合理的第一点聚焦探头型号3(晶片直径和焦距)和水层厚度,将实际聚焦区域调节至待检测钢球1底部的位置,从而提高超声波对钢球内部缺陷的灵敏度,并改善缺陷信号的信噪比。This can be based on the expression formula of the above-mentioned actual focal length f' to select a reasonable first point focusing probe model 3 (chip diameter and focal length) and water layer thickness, and adjust the actual focusing area to the position at the bottom of the steel ball 1 to be detected, thereby improving the ultrasonic Sensitivity to internal defects of steel balls and improved signal-to-noise ratio of defect signals.
在无损检测领域,平底孔一般为金属内部缺陷的人工标准缺陷模式。图4A为钢球平底孔缺陷示意图,图中D表示钢球直径,d表示平底孔缺陷的直径,h表示平底孔缺陷的深度;图4B至图4F为不同深度的钢球平底孔缺陷的回波信号示意图;图4B至图4F所示波形图是在图1所示的实施装置上,用本发明提供的上述检测方法检测直径φ54mm钢球中不同深度的直径φ0.5mm的平底孔缺陷所得到的信号波形图,图中波形图的圆圈圈定部分为缺陷位置的波形,检测过程中第一点聚焦探头3选用的型号是:晶片直径10mm、焦距59.4mm,水层厚度为19.5mm。分析图中检测信号可知:在待检测钢球1的底波信号前找到了平底孔缺陷的回波信号,且缺陷信号与底波信号之间的声程差与平底孔的深度值基本一致。由此能够推断:当第一点聚焦探头3的声源轴线与待检测钢球1球心共线时,通过选择合理的探头参数(晶片直径和焦距)和水层厚度,将实际聚焦区域调节至待检测钢球1底部的位置,若待检测钢球1的内部缺陷位于探头的声源轴线上,可在待检测钢球1的底波信号前找到信噪比较好的缺陷回波信号。In the field of non-destructive testing, flat-bottomed holes are generally artificial standard defect patterns of internal defects in metals. Figure 4A is a schematic diagram of steel ball flat-bottomed hole defects, in which D represents the diameter of the steel ball, d represents the diameter of the flat-bottomed hole defect, and h represents the depth of the flat-bottomed hole defect; Fig. 4B to Fig. Wave signal schematic diagram; Waveform diagram shown in Fig. 4B to Fig. 4F is on the implementation device shown in Fig. 1, detects the flat-bottomed hole defect of the diameter φ0.5mm of different depths in the diameter φ54mm steel ball with the above-mentioned detection method that the present invention provides The obtained signal waveform diagram, the circled part of the waveform diagram in the figure is the waveform of the defect position. The model selected for the first point focusing probe 3 in the detection process is: the diameter of the wafer is 10mm, the focal length is 59.4mm, and the thickness of the water layer is 19.5mm. Analysis of the detection signal in the figure shows that the echo signal of the flat-bottomed hole defect is found before the bottom wave signal of the steel ball 1 to be detected, and the sound path difference between the defect signal and the bottom wave signal is basically consistent with the depth value of the flat-bottomed hole. It can be deduced that: when the sound source axis of the first point focusing probe 3 is collinear with the center of the steel ball 1 to be detected, the actual focus area can be adjusted by selecting reasonable probe parameters (chip diameter and focal length) and water layer thickness. To the bottom of the steel ball 1 to be detected, if the internal defect of the steel ball 1 to be detected is located on the sound source axis of the probe, the defect echo signal with a better signal-to-noise ratio can be found before the bottom wave signal of the steel ball 1 to be detected .
根据第二点聚焦探头3’发射的超声波在交质界面的折射定律及斯奈尔定律,调节第二点聚焦探头3’的位置,使其声源轴线偏离待检测钢球1的球心达到设定距离,使进入待检测钢球1内的超声波转换为横波,实现对待检测钢球1的表面缺陷检测。如图5所示,图5为本发明提供的超声折射定律的原理示意图,图中α表示超声波入射角,αs’表示横波反射角,αL’表示纵波反射角,βs表示横波折射角,βL表示纵波折射角。根据超声波在液固交界面(即交质界面)的折射定律和斯奈尔定律,调节第二点聚焦探头3’的声源轴线与待检测钢球1球心之间的偏心距,使第二点聚焦探头3’发射的纵波在交界面转换成横波进入待检测钢球1内,从而实现对待检测钢球1的表面缺陷检测。According to the law of refraction and Snell's law of the ultrasonic waves emitted by the second point focusing probe 3' at the interface between substances, the position of the second point focusing probe 3' is adjusted so that the axis of the sound source deviates from the center of the steel ball 1 to be detected. The distance is set so that the ultrasonic waves entering the steel ball 1 to be detected are converted into transverse waves, so as to realize the detection of surface defects of the steel ball 1 to be detected. As shown in Figure 5, Figure 5 is a schematic diagram of the principle of the ultrasonic refraction law provided by the present invention, in which α represents the ultrasonic incident angle, α s ' represents the shear wave reflection angle, α L ' represents the longitudinal wave reflection angle, and β s represents the shear wave refraction angle , β L represents the longitudinal wave refraction angle. According to the refraction law and Snell's law of ultrasonic waves at the liquid-solid interface (i.e., the interface with matter), adjust the eccentric distance between the sound source axis of the second point focusing probe 3' and the center of the steel ball 1 to be detected, so that the first The longitudinal wave emitted by the two-point focusing probe 3' is converted into a transverse wave at the interface and enters the steel ball 1 to be detected, thereby realizing the detection of surface defects of the steel ball 1 to be detected.
如图6A1至图6A8所示,图6A1至图6A8为本发明提供的钢球各类表面缺陷的回波信号示意图,图中圆圈圈定的部分均为钢球缺陷所在位置的波形图;其中,图6A1为无凹坑缺陷的波形图,图6A2为存在凹坑缺陷的回波信号波形图;图6A3为无群点缺陷的波形图,图6A4为存在群点缺陷的回波信号波形图;图6A5为无划伤缺陷的波形图,图6A6为存在划伤缺陷的回波信号波形图;图6A7为无点子缺陷的波形图,图6A8为存在点子缺陷的回波信号波形图。图6A1至图6A8所示波形图是在图1所示的实施装置上,用本发明提供的上述检测方法检测直径φ54mm钢球中常见表面缺陷所得到的信号波形图,检测过程中第二点聚焦探头3’与第一点聚焦探头3的探头型号及水层厚度一致,第二点聚焦探头3’的声源轴线与待检测钢球1球心的偏心距为3mm。分析检测所得信号可知:针对钢球加工过程中出现的凹坑、群点、划伤、点子等缺陷,本发明提供的检测方法均能够较好的检出。As shown in Figures 6A1 to 6A8, Figures 6A1 to 6A8 are schematic diagrams of echo signals of various surface defects of steel balls provided by the present invention, and the circled parts in the figures are waveform diagrams of the positions of steel ball defects; among them, Figure 6A1 is a waveform diagram without pit defects, Figure 6A2 is an echo signal waveform diagram with pit defects; Figure 6A3 is a waveform diagram without cluster point defects, and Figure 6A4 is an echo signal waveform diagram with cluster point defects; Figure 6A5 is a waveform diagram without scratch defects, Figure 6A6 is an echo signal waveform diagram with scratch defects; Figure 6A7 is a waveform diagram without dot defects, and Figure 6A8 is an echo signal waveform diagram with dot defects. The waveform diagrams shown in Fig. 6A1 to Fig. 6A8 are signal waveform diagrams obtained by using the above-mentioned detection method provided by the present invention to detect common surface defects in steel balls with a diameter of φ54mm on the implementation device shown in Fig. 1, the second point in the detection process The focus probe 3' is consistent with the probe type and water layer thickness of the first point focus probe 3, and the eccentric distance between the sound source axis of the second point focus probe 3' and the center of the steel ball 1 to be detected is 3 mm. It can be seen from the analysis of the detected signals that the detection method provided by the present invention can better detect defects such as pits, group spots, scratches, and dots that occur during the processing of steel balls.
本发明提供的基于点聚焦探头(3,3’)的钢球超声探伤方法,其原理是基于超声波在固体内传播时遇到缺陷后会发生反射,反射波经探头接收再转换成电信号,经接收电路放大、滤波和A/D转换等处理后在计算机数据处理系统上显示出能够表征缺陷的回波信号。本发明中检测待检测钢球1内部缺陷的原理是:第一点聚焦探头3声源轴线上的声压是最强的,当待检测钢球1内部缺陷处于声源轴线上时,不仅能够得到信噪比较好的缺陷回波,也增加了对内部缺陷的灵敏度。本发明中检测待检测钢球1表面缺陷的原理是:通过改变第二点聚焦探头3’发射的超声波的入射角度,使其进入待检测钢球1内部后转换成横波,横波对待检测钢球1表面的缺陷更加灵敏。The steel ball ultrasonic flaw detection method based on point focusing probes (3, 3') provided by the present invention is based on the principle that ultrasonic waves will reflect when encountering defects when propagating in a solid, and the reflected waves are received by the probe and then converted into electrical signals. After being amplified, filtered and A/D converted by the receiving circuit, the echo signal that can represent the defect is displayed on the computer data processing system. The principle of detecting the internal defect of the steel ball 1 to be detected in the present invention is: the sound pressure on the axis of the sound source of the first point focusing probe 3 is the strongest, when the internal defect of the steel ball 1 to be detected is on the axis of the sound source, not only can The defect echo with good signal-to-noise ratio is obtained, and the sensitivity to internal defects is also increased. The principle of detecting the surface defects of the steel ball 1 to be detected in the present invention is: by changing the incident angle of the ultrasonic wave emitted by the second point focusing probe 3', it is converted into a transverse wave after entering the steel ball 1 to be detected, and the transverse wave is converted into a transverse wave of the steel ball to be detected 1 Surface defects are more sensitive.
本发明的技术方案不仅可以检测待检测钢球1的表面缺陷,也能够检测待检测钢球1的内部缺陷,弥补现有技术对钢球的探伤盲点。本发明中通过分析点聚焦探头(3,3’)在待检测钢球1内实际焦距,选择点聚焦探头(3,3’)的参数与水层厚度,有效提高了超声波对钢球内部缺陷的灵敏度,并改善缺陷回波的信噪比。本发明能够对不同直径规格的钢球进行缺陷检测,通用性和互换性强。本发明提供的基于点聚焦探头的钢球超声探伤装置结构简单,操作方便,使用安全,通用性强,成本低,检测精度高,易于实现钢球的自动化探伤,对保证钢球质量,提高轴承可靠性等具有重要意义,适宜推广应用,具有广阔的市场应用前景。The technical scheme of the present invention can not only detect the surface defect of the steel ball 1 to be detected, but also detect the internal defect of the steel ball 1 to be detected, so as to make up for the blind spot of flaw detection of the steel ball in the prior art. In the present invention, by analyzing the actual focal length of the point-focusing probe (3, 3') in the steel ball 1 to be detected, the parameters of the point-focusing probe (3, 3') and the thickness of the water layer are selected, which effectively improves the impact of ultrasonic waves on the internal defects of the steel ball. sensitivity and improve the signal-to-noise ratio of defect echoes. The invention can detect the defects of steel balls with different diameters and specifications, and has strong versatility and interchangeability. The steel ball ultrasonic flaw detection device based on the point focusing probe provided by the present invention is simple in structure, easy to operate, safe to use, strong in versatility, low in cost, high in detection accuracy, and easy to realize automatic flaw detection of steel balls, which is very important for ensuring the quality of steel balls and improving the quality of bearings. Reliability, etc. are of great significance, suitable for popularization and application, and have broad market application prospects.
注意,上述仅为本发明的较佳实施例及所运用技术原理。本领域技术人员会理解,本发明不限于这里所述的特定实施例,对本领域技术人员来说能够进行各种明显的变化、重新调整和替代而不会脱离本发明的保护范围。因此,虽然通过以上实施例对本发明进行了较为详细的说明,但是本发明不仅仅限于以上实施例,在不脱离本发明构思的情况下,还可以包括更多其他等效实施例,而本发明的范围由所附的权利要求范围决定。Note that the above are only preferred embodiments of the present invention and applied technical principles. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and that various obvious changes, readjustments and substitutions can be made by those skilled in the art without departing from the protection scope of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments, and can also include more other equivalent embodiments without departing from the concept of the present invention, and the present invention The scope is determined by the scope of the appended claims.
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