Study on quantitative detection of fatigue cracks for hollow axles on high-speed trains by the total focus method

HUANG Yongcong; ZHAO Menglin; TAN Yuanhao

doi:10.13890/j.issn.1000-128X.2022.06.006

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Study on quantitative detection of fatigue cracks for hollow axles on high-speed trains by the total focus method

Railway Rolling Stock | 更新时间：2024-08-02

- Study on quantitative detection of fatigue cracks for hollow axles on high-speed trains by the total focus method
- Electric drive for locomotives Issue 6, Pages: 39-43(2022)
- 作者机构：
  
  1.国能新朔铁路有限责任公司，内蒙古鄂尔多斯　　010318
  2.北京主导时代科技有限公司，北京　　100070
  3.西南交通大学物理科学与技术学院，四川成都　　610031
- 作者简介：
- 基金信息：
- DOI：10.13890/j.issn.1000-128X.2022.06.006
  CLC： U292.91⁺4;U270.331⁺.1
- Published：10 November 2022，
  
  Received：13 January 2021，
- 稿件说明：
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HUANG Yongcong, ZHAO Menglin, TAN Yuanhao. Study on quantitative detection of fatigue cracks for hollow axles on high-speed trains by the total focus method. [J]. Electric drive for locomotives (6):39-43(2022)
DOI：

HUANG Yongcong, ZHAO Menglin, TAN Yuanhao. Study on quantitative detection of fatigue cracks for hollow axles on high-speed trains by the total focus method. [J]. Electric drive for locomotives (6):39-43(2022) DOI： 10.13890/j.issn.1000-128X.2022.06.006.

摘要

空心车轴是高速列车重要的组成部分，目前主要使用常规超声技术从内孔面检测空心车轴外表面的横向疲劳裂纹，以保障高速列车运行安全。但使用常规超声技术无法实现疲劳裂纹的量化检测，从而无法评估空心车轴下次探伤周期，为列车安全留下隐患。文章研究了双层介质下超声最短传播路径的几何模型，结合Snell定律和Ferrari方法，计算出超声波束在双层介质交界面处的入射点位置，从而实现双层介质中的全聚焦方法成像。试验结果表明，该方法可以提供线性界面入射点坐标的精确解，并且可以准确地重建疲劳裂纹图像。通过增加路径计算和波形转换状态的二次反射来改进模型，可以实现空心车轴的真实裂缝量化成像。试验结果可以清楚地显示裂纹的形状和生长趋势，但裂纹尖端的漫反射现象仍会对裂纹的定量分析产生一定影响。

Abstract

Among the important components on high-speed trains

hollow axles are detected from the inner bore surface for transverse fatigue cracks on the outer surface by the conventional ultrasonic technique

as a measure to ensure the operation safety of high-speed trains. However fatigue cracks cannot be quantified by this conventional technique

making it impossible to identify the next detection cycle of the hollow axle

leaving a safety loophole for the trains. In this study

the shortest path of ultrasonic propagation through the double-layer media was geometrically modeled. Applying the Snell's law and Ferrari’s method

the position was calculated for the incident point of the ultrasonic beam on the interface plane

to enable imaging in the double-layer media by the total focusing method（TFM）. According to the study results

this method can generate the exact solution of the coordinates at the incident point on a linear interface and accurately reconstruct the fatigue crack images. The model improved with additional path calculation and secondary reflection of waveform conversion status

can achieve the real crack quantitative imaging of hollow axles. The results clearly presented the shape and development tendency of cracks

but the diffuse reflection at the crack tip will cause a certain impact on the quantitative.

关键词

高速列车空心车轴疲劳裂纹全聚焦技术双层介质成像Snell定律

Keywords

high-speed trainhollow axlefatigue cracktotal focus methoddouble-layer media imagingSnell’s law

references

RICHTER C, FROEHLICH M, SCHOLZ H, et al. Development of components for an industry approved hollow-axle testing system[C]//BINDT. 18th World Conference on Non-Destructive Testing 2012 (WCNDT 2012). Durban, South Africa: BINDT, 2012: 2467-2473.

ROHRSCHNEIDER A, HINTZE H, OELSCHLÄGEL T. Further development of the ultrasonic testing of hollow axles[C]//EFNDT. 11th European Conference on Non-Destructive Testing (ECNDT 2014. Prague, Czech Republic: EFNDT, 2014: 2783-2791.

VÖLZ U, HEILMANN P, SPIEKER M. New approach for a more detailed visualisation of ultrasonic testing data of railway hollow axles[C]//NDT. 19th World Conference on Non-Destructive Testing 2016 (WCNDT 2016). Munich, Germany: NDT, 2016: 3358-3362.

MARTY P. Latest development in the UT inspection of train wheels and axles[C]//BINDT. 18th World Conference on Non-Destructive Testing 2012 (WCNDT 2012). Durban, South Africa: BINDT, 2012: 2523-2533.

HOLMES C, DRINKWATER B W, WILCOX P D. Post-processing of the full matrix of ultrasonic transmit–receive array data for non-destructive evaluation[J]. NDT & E International, 2005, 38(8): 701-711.

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MOREAU L, HUNTER A J, DRINKWATER B W, et al. Efficient imaging techniques using an ultrasonic array[C]//SPIE. Proceedings Volume 7650, Health Monitoring of Structural and Biological Systems 2010. San Diego, California, United States: SPIE, 2010: 765037.

SUTCLIFFE M, WESTON M, DUTTON B, et al. Real-time full matrix capture for ultrasonic non-destructive testing with acceleration of post-processing through graphic hardware[J]. NDT & E International, 2012, 51: 16-23.

ZHANG Jie, DRINKWATER B W, WILCOX P D, et al. Defect detection using ultrasonic arrays: the multi-mode total focusing method[J]. NDT & E International, 2010, 43(2): 123-133.

LONG R, RUSSELL J, CAWLEY P. Ultrasonic phased array inspection using full matrix capture[J]. Insight- Non-Destructive Testing and Condition Monitoring, 2012, 54(7): 380-385.

WESTON M, MUDGE P, DAVIS C, et al. Time efficient auto-focussing algorithms for ultrasonic inspection of dual-layered media using full matrix capture[J]. NDT & E International, 2012, 47: 43-50.

WESTON M, NAGESWARAN C, SUTCLIFFE M, et al. Calibration of ultrasonic techniques using full matrix capture data for industrial inspection[J]. Insight-Non-Destructive Testing and Condition Monitoring, 2012, 54(11): 602-611.

SUTCLIFFE M, WESTON M, CHARLTON P, et al. Full matrix capture with time-efficient auto-focusing of unknown geometry through dual-layered media[J]. Insight-Non-Destructive Testing and Condition Monitoring, 2013, 55(6): 297-301.

ZHANG Jie, DRINKWATER B W, WILCOX P D. The use of ultrasonic arrays to characterize crack-like defects[J]. Journal of Nondestructive Evaluation, 2010, 29(4): 222-232.

MACDUFFEE C C. Theory of equations[M]. New York: Wiley, 1954.

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