CN-121978220-A - Ultrasonic radial detection calibration test block and detection method for wheel hub part of railway wagon

CN121978220ACN 121978220 ACN121978220 ACN 121978220ACN-121978220-A

Abstract

The application relates to the technical field of ultrasonic nondestructive testing of wheels of railway wagons, in particular to an ultrasonic radial detection calibration test block and a detection method for wheel hubs of railway wagons, wherein the ultrasonic radial detection calibration test block comprises a single test block integrating seven convex arc detection surfaces with phi 160mm to phi 220mm, radial flat bottom holes with phi 3mm and 5/35/55mm depth are arranged below each detection surface, and the materials are consistent with the wheels; the matched detection method is used for manufacturing a distance amplitude curve through the matched probe and standardizing scanning parameters and defect judging rules. The application can realize the precise calibration of the detection sensitivity under the multi-specification hub aperture and the consistency transfer of the defect equivalent, and improve the detection accuracy and efficiency.

Inventors

DING SHOULI
GAO WEIWEN
WU WENBING
ZHANG LEI
WU JI
Ni Shihai
DONG ZHIWEI

Assignees

中车长江铜陵车辆有限公司

Dates

Publication Date: 20260505
Application Date: 20260319

Claims (10)

1. The ultrasonic radial detection calibration test block for the wheel hub of the railway wagon is of an integral metal structure and is characterized by comprising 7 independent convex arc detection surfaces which are distributed along the end face of the test block in an annular or sector array mode, wherein the diameters of the convex arc detection surfaces are phi 160 mm, phi 170 mm, phi 180 mm, phi 190 mm, phi 200 mm, phi 210 mm and phi 220 mm in sequence, the convex arc detection surfaces with specific curvature radiuses are formed on the circumferential side face or the appointed end face of the test block in a machining mode, the whole calibration test block is in a cylindrical shape, the outer cylindrical surface is used as a reference surface, each convex arc detection surface is recessed by 3mm in the radial direction from the reference surface, the curvature radius of the convex arc detection surfaces is equal to half of the inner diameter of a corresponding hub hole to simulate the geometric shape of the inner wall of the hub hole, 3 artificial flat bottom holes (12) are arranged under each convex arc detection surface in the thickness direction of the test block, the diameters of the artificial flat bottom holes (12) are phi 3mm, the depths of 5mm, 35 mm and mm are 5, the ultrasonic sound beam is completely separated from the center holes of the adjacent concave bottom holes (38) in the axial direction along the direction, and the normal line of the center of the test hole is not perpendicular to the center of the test hole, and the adjacent concave bottom holes are completely cut off along the axial direction, and the center holes are not perpendicular to the center line of the center holes and the center holes are completely separated by the center holes and the 3 detection grooves are completely cut.
2. The ultrasonic radial detection calibration test block for the wheel hub of the railway wagon is characterized in that the calibration test block is made of CL60 or ER8 grade wheel steel, and the heat treatment state is normalizing and tempering, and the surface roughness Ra is less than or equal to 1.6 mu m.
3. An ultrasonic radial detection calibration block for a hub of a railway wagon wheel according to claim 2, wherein the machining depth tolerance of the manual flat bottom hole (12) is +/-0.1 mm, and the hole bottom is a flat plane without taper, chamfer or other geometric deviation.
4. The ultrasonic radial detection and calibration test block for the hub of the wagon wheel according to claim 1, wherein each group of manual flat bottom holes (12) are arranged in a staggered manner in the circumferential direction, and positioning marks for identifying the target detection surface and the positions of the corresponding manual flat bottom holes (12) are arranged on the surface of the test block.
5. An ultrasonic radial inspection calibration block for a railway wagon wheel hub as defined in claim 4, wherein said positioning marks are mechanical scores or laser marks.
6. A method for ultrasonic radial detection of a wheel hub part of a railway wagon based on a calibration test block according to any one of claims 1 to 5 is characterized by comprising the following steps of S1, selecting a convex arc detection surface with the same aperture on the calibration test block according to the actual inner diameter size of a wheel hub hole (25) to be detected, selecting a convex arc probe (11) with the same curvature diameter, uniformly coating a coupling agent with the same type, viscosity and thickness used for formal detection on the detection surface, S2, placing the convex arc probe (11) on a target convex arc detection surface, sequentially detecting artificial flat bottom holes (12) with 3 depths corresponding to the detection surface, adjusting the gain of an ultrasonic detector to enable the maximum reflected echo height of each flat bottom hole (12) to reach 50% of the full width of a fluorescent screen, recording corresponding acoustic values and wave amplitudes, and adopting an exponential attenuation model according to the sound velocity and attenuation coefficient of materials: fitting was performed on three-point data of 5 mm, 35, mm, 55, mm, wherein A (d) is the sound pressure amplitude of the ultrasonic wave after the propagation distance is d, A 0 is the initial sound pressure amplitude of the ultrasonic wave, e -ad is an exponential attenuation factor, a distance amplitude curve in the range of 0-80 and mm is extrapolated, S3 is carried out on the inner wall of a wheel hub hole (25) to be detected, a coupling agent which is the same as that used in calibration is coated, a convex arc probe (11) with matched curvature is closely attached to the inner wall of the wheel hub hole (25), the center line of the probe beam is kept along the radial direction of the wheel hub hole (25), the center of the probe curvature coincides with the axis of the wheel hub hole, the probe performs spiral scanning along the circumferential direction and the axial composite motion of the wheel hub hole (25) at a speed of not more than 150 mm/S, the overlapping area between adjacent scanning tracks is not less than 10% of the effective size of a probe wafer, S4 is carried out when a defect echo is found in the detection process, the highest amplitude position of the probe is located, the depth value and the corresponding to the defect amplitude is read, the defect amplitude curve is compared with the distance curve at the same depth, the defect amplitude value is recorded as the defect amplitude value, if the defect amplitude value is higher than the defect amplitude value, the defect amplitude value is recorded as the defect amplitude value is judged as the defect amplitude value, and the defect waveform value is judged as the waveform value.
7. The ultrasonic radial detection method for the hub part of the wagon wheel according to claim 6, wherein the distance amplitude curve is established according to the requirement on the radial detection sensitivity of the hub part in the TB/T2817-2018 standard, and a phi 3 mm flat bottom hole is used as a reference reflector.
8. The ultrasonic radial detection method for the hub of the wagon wheel according to claim 6, wherein the working surface of the front end of the convex arc probe (11) is a convex arc surface matched with the curvature of the inner wall of the hub hole (25).
9. The ultrasonic radial detection method for the hub of the wagon wheel according to claim 6, wherein the axial direction of the artificial flat-bottom hole (12) is arranged radially along the radial direction of the hub so that the ultrasonic beam is approximately perpendicularly incident to the bottom surface of the artificial flat-bottom hole (12).
10. The ultrasonic radial detection method for the hub of the wagon wheel according to claim 6, wherein the calibration block is consistent with the material, the heat treatment state and the surface roughness of the inspected wagon wheel.

Description

Ultrasonic radial detection calibration test block and detection method for wheel hub part of railway wagon Technical Field The invention belongs to the technical field of nondestructive testing, and relates to an ultrasonic radial detection calibration test block and a detection method for a wheel hub part of a railway wagon. Background The wheels of the railway freight car are used as key bearing components in a running system of the railway freight car, and the structural integrity and the internal quality of the wheels are directly related to the safety and the reliability of the running of the railway freight car. In order to prevent sudden failure caused by fatigue cracks or internal defects, ultrasonic nondestructive testing has been widely used in the links of factory inspection and overhaul maintenance of wheels. According to the requirements of the current industry standard TB/T2817-2018, the axial ultrasonic detection and the radial ultrasonic detection are required to be carried out on the hub part of the wheel, wherein the radial detection is required to be carried out through the inner wall of the hub hole. Due to the limitations of hub bore geometry, a convex arc probe must be used that matches the bore diameter to ensure good acoustic coupling and efficient acoustic energy transfer. However, the hub hole of the wheels used in the railway freight car at present has various inner diameter specifications, which cover 7 sizes from phi 160mm to phi 220mm, and different apertures correspond to different incidence angles, propagation paths and focusing characteristics of sound beams. If the unified calibration test block is adopted for sensitivity calibration, the artificial defect echo equivalent distortion is caused, and the accuracy of detection sensitivity setting and the consistency of defect judgment are further affected. In the prior art, the ultrasonic detection calibration sample wheel with the publication number of CN216117473U integrates the artificial defects (artificial flat bottom holes) of rims, treads, webs and hub areas, can be used for integral sensitivity verification and blind area coverage rate evaluation, but adopts an integral structure with fixed size, does not carry out modularization or alternative design on different hub apertures, and is only suitable for wheels with single specification. In particular, in the radial detection of the hub part, the sample wheel cannot simulate the actual acoustic response conditions of the convex arc probe under different apertures, so that the calibration result is disjointed from the actual detection working condition, and the accurate equivalent calibration requirement under the multi-specification hub aperture is difficult to meet. The other publication No. CN205157499U discloses a sample wheel for ultrasonic detection wheel, which is provided with flat bottom holes with different depths in a hub area to improve calibration efficiency, but is still of an integral casting structure, the hub hole is fixed in size and cannot adapt to various apertures with phi 160mm to phi 220mm, meanwhile, the scheme does not consider the influence of probe curvature and hub hole matching on sound field distribution, and the arrangement of artificial defects is not optimized according to sound beam focusing characteristics under different apertures, so that systematic deviation exists in calibration sensitivity. In addition, the above patents do not propose a standardized detection method matched with the aperture of the hub with multiple specifications, lack of standard guidance on key parameters such as gain compensation, scanning paths and the like, and are difficult to support the implementation of high-consistency or automatic detection flow. In summary, although the existing calibration sample wheel has advanced in terms of function integration, there are still significant disadvantages in terms of the specificity of ultrasonic radial detection at the hub part, suitability for multiple specifications, and cooperativity of the detection method. Therefore, development of a serial calibration test block capable of realizing accurate acoustic simulation for different hub apertures is needed, and a standardized detection method is established in a matched manner so as to ensure accurate transmission of defect equivalent and high consistency of detection results, thereby effectively supporting safe service and quality control of wheels of railway trucks. Disclosure of Invention Aiming at the technical defects that the prior calibration test block adopted in the ultrasonic radial detection of the wheel hub part of the railway wagon cannot be matched with the aperture of a wheel hub with multiple specifications, the artificial defect arrangement mode is inconsistent with the actual sound field characteristic, the calibration process is disjointed with the detection process and the like, the invention provides a serial calibration test block with integrate