基于全聚焦相控阵的机车车轮浅表层裂纹检测方法  

Research on Superficial Crack Detection Method of Locomotive Wheels Based on Total Focusing Phased Array

作　　者：杨兴宽 潘碧琳 黄永巍 李立凡 赵光波 黄浩 YANG Xingkuan;PAN Bilin;HUANG Yongwei;LI Lifan;ZHAO Guangbo;HUANG Hao(Metals&Chemistry Research Institute,China Academy of Railway Sciences Corporation Limited,Beijing 100081,China;Kunming Locomotive Depot,China Railway Kunming Group Co.,Ltd.,Kunming Yunnan 650217,China;Chongqing Locomotive Depot,China Railway Chengdu Group Co.,Ltd.,Chongqing 401335,China)

机构地区：[1]中国铁道科学研究院集团有限公司金属及化学研究所,北京100081 [2]中国铁路昆明局集团有限公司昆明机务段,云南昆明650217 [3]中国铁路成都局集团有限公司重庆机务段,重庆401335

出　　处：《中国铁路》2025年第2期81-88,共8页China Railway

基　　金：中国国家铁路集团有限公司科技研究开发计划项目(J2022J007)。

摘　　要：针对机车不落轮旋修时,车轮浅表层缺陷难以检测、缺陷深度难以准确测量的问题,提出基于全聚焦算法(Total Focusing Method,TFM)的相控阵超声检测方法。根据不落轮旋修工位特点及检测需求设计工艺参数,通过CIVA仿真建模验证TFM对浅表层裂纹检测成像的可行性和准确性,利用人工试块检测,研究不同角度和深度裂纹的回波特性,仿真和人工试块实验中裂纹深度的检测误差均可控制在7.00%以下,表明该方法可有效检测车轮中的浅表层裂纹。应用于某机务段机车不落轮旋修工位的实测中发现,经旋修证实共有9片车轮含浅表层裂纹,且最小裂纹深度为1.80 mm,裂纹深度检测误差平均值为0.63 mm,表明该方法检测盲区至少可缩小至踏面下1.80 mm,与现行标准5.00 mm相比缩小了64.00%。结果表明,该检测方法可准确检测机车车轮浅表层裂纹并定位深度,可为机车检修效率提高、经济性旋修模型优化提供技术支持。In response to the challenges of detecting superficial defects and accurately measuring defect depths during underfloor wheel reprofiling of locomotives,this paper proposes a phased array ultrasonic testing method based on the total focusing method(TFM).Based on the characteristics of the underfloor wheel reprofiling station and the detection requirements,process parameters are designed.The feasibility and accuracy of TFM for detecting and imaging superficial cracks are verified through CIVA simulation modeling.By utilizing artificial test blocks,the echo characteristics of cracks at different angles and depths are studied.The detection error for crack depth in both simulation and experimental tests with artificial test blocks can be controlled to within 7.00%,indicating that this method is effective for detecting superficial cracks in wheels.This method was applied at a locomotive underfloor wheel reprofiling station in a certain locomotive depot.During practical measurements,it was found and confirmed through reprofiling that nine wheels contained superficial cracks,with the minimum crack depth of 1.80 mm.The average detection error for crack depth was 0.63 mm,indicating that the detection blind zone can be reduced to at least 1.80 mm beneath the tread,representing a 64.00%reduction compared to the current standard of 5.00 mm.The results indicate that this detection method can accurately detect superficial cracks in locomotive wheels and determine their depth.This provides technical support for improving the efficiency of locomotive maintenance and optimizing the economic reprofiling model.

关 键 词：机车车轮 不落轮旋修 裂纹检测 相控阵超声检测 全聚焦算法 

分 类 号：U269[机械工程—车辆工程]