Chinese Journal of Mechanical Engineering >

2021 , Vol. 34 >Issue 6: 114 - 114

DOI: https://doi.org/10.1186/s10033-021-00637-5

Original Article

Modeling and Experimental Analysis of Roughness Effect on Ultrasonic Nondestructive Evaluation of Micro-crack

  • Zhe Wang ,
  • Zhichao Fan ,
  • Xuedong Chen ,
  • Yihua Kang ,
  • Jingwei Cheng ,
  • Wei Chen
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  • 1 National Safety Engineering Technology Research Center for Pressure Vessels and Pipeline, Hefei General Machinery Research Institute Co., Ltd, Hefei, 230031, China;
    2 State Key Lab of Digital Manufacturing Equipment & Technology, Huazhong University of Science and Technology, Wuhan, 430074, China
Zhe Wang, born in 1991, is currently an assistant research fellow at Hefei General Machinery Research Institute Co., Ltd., China. He received his BSc and PhD from School of Mechanical Science & Engineering at Huazhong University of Science and Technology, China, in 2013 and 2019, respectively. His research interests include nondestructive testing technology and instrumentation development, such as piezoelectric/electromagnetic ultrasonic inspection;
Zhichao Fan, born in 1974, is currently a research fellow at Hefei General Machinery Research Institute Co., Ltd., China. He received his PhD degree on chemical engineering and machinery in Zhejiang University, China, in 2004;
Xuedong Chen, born in 1964, is currently an Academician of Chinese Academy of Engineering at Hefei General Machinery Research Institute Co., Ltd., China. He received his PhD degree on chemical engineering and machinery in Zhejiang University, China, in 2004;
Yihua Kang, born in 1965, is currently a professor at Huazhong University of Science and Technology, China. He received his PhD degree from Huazhong University of Science and Technology, China, in 1993. His research interests include nondestructive testing technology and instrumentation;
Jingwei Cheng, born in 1993, is currently an assistant research fellow at Hefei General Machinery Research Institute Co., Ltd., China. He received his PhD degree from Bristol University, UK, in 2018. His research interests include nondestructive testing technology and instrumentation;
Wei Chen, born in 1980, is currently a senior engineer at Hefei General Machinery Research Institute Co., Ltd., China. His main research interests include risk-based inspection of petrochemical installations

收稿日期: 2020-12-30

  修回日期: 2021-08-16

  网络出版日期: 2022-04-03

基金资助

Supported by the Key Research and Development Plan of Anhui Province (Grant No. 202004a05020003), Anhui Provincial Natural Science Foundation (Grant Nos. 2008085QE233, 2008085J24), the Science and Technology Major Project of Anhui Province (Grant No. 201903a05020010) and the Doctoral Science and Technology Foundation of Hefei General Machinery Research Institute (Grant No. 2019010383).

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Modeling and Experimental Analysis of Roughness Effect on Ultrasonic Nondestructive Evaluation of Micro-crack

  • Zhe Wang ,
  • Zhichao Fan ,
  • Xuedong Chen ,
  • Yihua Kang ,
  • Jingwei Cheng ,
  • Wei Chen
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  • 1 National Safety Engineering Technology Research Center for Pressure Vessels and Pipeline, Hefei General Machinery Research Institute Co., Ltd, Hefei, 230031, China;
    2 State Key Lab of Digital Manufacturing Equipment & Technology, Huazhong University of Science and Technology, Wuhan, 430074, China

Received date: 2020-12-30

  Revised date: 2021-08-16

  Online published: 2022-04-03

Supported by

Supported by the Key Research and Development Plan of Anhui Province (Grant No. 202004a05020003), Anhui Provincial Natural Science Foundation (Grant Nos. 2008085QE233, 2008085J24), the Science and Technology Major Project of Anhui Province (Grant No. 201903a05020010) and the Doctoral Science and Technology Foundation of Hefei General Machinery Research Institute (Grant No. 2019010383).

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摘要

A high-precision evaluation of ultrasonic detection sensitivity for a micro-crack can be restricted by a corroded rough surface when the surface microtopography is of the same order of magnitude as the crack depth. In this study, a back-surface micro-crack is considered as a research target. A roughness-modified ultrasonic testing model for micro-cracks is established based on a multi-Gaussian beam model and the principle of phase-screen approximation. The echo signals of micro-cracks and noises corresponding to different rough front surfaces and rough back surfaces are obtained based on a reference reflector signal acquired from a two-dimensional simulation model. Further comparison between the analytical and numerical models shows that the responses of micro-cracks under the effects of different corroded rough surfaces can be accurately predicted. The numerical and analytical results show that the echo signal amplitude of the micro-crack decreases significantly with an increase in roughness, whereas the noise amplitude slightly increases. Moreover, the effect of the rough front surface on the echo signal of the micro-crack is greater than that of the rough back surface. When the root-mean-square (RMS) height of the surface microtopography is less than 15 μm, the two rough surfaces have less influence on the echo signals detected by a focused transducer with a frequency of 5 MHz and diameter of 6 mm. A method for predicting and evaluating the detection accuracy of micro-cracks under different rough surfaces is proposed by combining the theoretical model and a finite element simulation. Then, a series of rough surface samples containing different micro-cracks are fabricated to experimentally validate the evaluation method.

关键词： Surface roughness; Micro-crack; Ultrasonic testing model; Detection accuracy; Evaluation method

本文引用格式

Zhe Wang , Zhichao Fan , Xuedong Chen , Yihua Kang , Jingwei Cheng , Wei Chen . Modeling and Experimental Analysis of Roughness Effect on Ultrasonic Nondestructive Evaluation of Micro-crack[J]. Chinese Journal of Mechanical Engineering, 2021 , 34(6) : 114 -114 . DOI: 10.1186/s10033-021-00637-5

Abstract

A high-precision evaluation of ultrasonic detection sensitivity for a micro-crack can be restricted by a corroded rough surface when the surface microtopography is of the same order of magnitude as the crack depth. In this study, a back-surface micro-crack is considered as a research target. A roughness-modified ultrasonic testing model for micro-cracks is established based on a multi-Gaussian beam model and the principle of phase-screen approximation. The echo signals of micro-cracks and noises corresponding to different rough front surfaces and rough back surfaces are obtained based on a reference reflector signal acquired from a two-dimensional simulation model. Further comparison between the analytical and numerical models shows that the responses of micro-cracks under the effects of different corroded rough surfaces can be accurately predicted. The numerical and analytical results show that the echo signal amplitude of the micro-crack decreases significantly with an increase in roughness, whereas the noise amplitude slightly increases. Moreover, the effect of the rough front surface on the echo signal of the micro-crack is greater than that of the rough back surface. When the root-mean-square (RMS) height of the surface microtopography is less than 15 μm, the two rough surfaces have less influence on the echo signals detected by a focused transducer with a frequency of 5 MHz and diameter of 6 mm. A method for predicting and evaluating the detection accuracy of micro-cracks under different rough surfaces is proposed by combining the theoretical model and a finite element simulation. Then, a series of rough surface samples containing different micro-cracks are fabricated to experimentally validate the evaluation method.

Key words： Surface roughness; Micro-crack; Ultrasonic testing model; Detection accuracy; Evaluation method

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