无缝钢管无损检测技术的比较和研究

I无缝钢管无损检测技术的比较和研究摘 要无缝钢管作为一种经济断面钢材在个别领域中得到了广泛的应用。因此作为一种高应用价值的材料而对其无损检测的方式和理论的研究就显得尤为重要了。通过专业仪器设备的无损检测，能够在不损坏产品的前提下，将产品内在的质量问题尽可能地检测出来，最大程度地杜绝有质量缺陷的产品出厂，有效的避免质量事故的发生。轴 类 零 件 是 机 器 中 经 常 遇 到 的 典 型 零 件 之 一 。 它 主 要 用 来 支 承 传 动 零 部 件， 传 递 扭 矩 和 承 受 载 荷 。 轴 类 零 件 是 旋 转 体 零 件 ， 其 长 度 大 于 直 径 ， 一 般 由 同心 轴 的 外 圆 柱 面 、 圆 锥 面 、 内 孔 和 螺 纹 及 相 应 的 端 面 所 组 成 。 根 据 结 构 形 状 的不 同 ， 轴 类 零 件 可 分 为 光 轴 、 阶 梯 轴 、 空 心 轴 和 曲 轴 等 。关键词：断面钢材，无损检测，专业 ，前提IIABSTRACTSeamless steel tube as an economic profile steel in individual domain has been widely applied. Therefore, as a kind of high application value for the material of nondestructive testing and theoretical research is particularly important.Through professional equipment, can be in nondestructive testing of products do not damage, under the precondition of product the quality problem of the inner as far as possible to the greatest extent, prevent the products with quality defects, avoid quality accident.Machine shaft is frequently encountered one of the typical components. It is mainly used to support transmission parts, transmission torque and load to bear. Shaft is rotating body parts, its length greater than diameter, generally cylindrical shaft concentric cylinder, cone, bore and thread, and composed of the corresponding end. According to the structure of different shapes, can be divided into the optical axis shaft, stepped shaft, hollow shaft and the crank.KEY WORDS：section steel, nondestructive testing, professional, premiseIII目录前 言 .1第 一 章 无 缝 钢 管 简 介 .21.1 无缝钢管的介绍 .21.2 无缝钢管的分类 .3第 二 章 无 缝 钢 管 的 特 征 .52.1 无缝钢管的制造工艺 .52.2 无缝钢管的执行标准 .6第 三 章 无 缝 钢 管 的 性 能 .83.1 无缝钢管的力学性能 .83.2 无缝钢管的热处理 .103.3 无缝钢管质量的计算 .11第 四 章 无 缝 钢 管 的 用 途 .134.1 轴类零件的功用、结构特点及技术要求 .134.2 轴类零件的毛坯和材料 .14第 五 章 无 缝 钢 管 无 损 检 测 技 术 .155.1 电磁超声波技术在钢管无损检测中的应用 .155.1.1 罗伦兹力机理 .155.1.2 磁致伸缩力机理 .155.1.3 电磁超声波探伤系统 .165.2 组合无损检测技术 .175.2.1 常规无损检测分析 .185.3 无缝钢管硬度检测 .23参考文献 .28附 录 .30外文资料翻译 .341前言随着中国当前的经济形势的日趋好转，在“实现中华民族的伟大复兴”口号的倡引下，中国的制造业也日趋蓬勃发展；而无缝钢管无损检测技术已成为衡量一个国家制造业水平的重要标志之一，无缝钢管工业能促进工业产品生产的发展和质量提高，并能获得极大的经济效益，因而引起了各国的高度重视和赞赏。可见无缝钢管工业在国民经济中重要地位。我国对无缝钢管工业的发展也十分重视。无缝钢管作为一种经济断面钢材在个别领域中得到了广泛的应用。因此作为一种高应用价值的材料而对其无损检测的方式和理论的研究就显得尤为重要了。本次毕业设计的主要任务是通过专业仪器设备的无损检测，能够在不损坏产品的前提下，将产品内在的质量问题尽可能地检测出来，最大程度地杜绝有质量缺陷的产品出厂，有效的避免质量事故的发生。同时，通过查阅大量资料、手册、标准、期刊等，结合教材上的知识对无缝钢管的组成结构进一步理解认识，拓宽视野，丰富知识，建立无缝钢管无损检测技术的基本框架和思路，为将来独立完成无损检测积累经验。2第 一 章 无 缝 钢 管 简 介1.1 无缝钢管的介绍无 缝 钢 管 是 一 种 空 截 面 ， 围 绕 钢 带 无 接 缝 。 第 一 个 中 空 的 渠 道 ， 如 运 输 ，石 油 运 输 ， 天 然 气 ， 煤 气 ， 水 和 一 些 固 体 物 质 ， 管 道 等 流 体 ， 大 量 钢 管 。 实 心钢 管 和 圆 钢 等 相 比 ， 在 弯 曲 ， 更 轻 的 扭 矩 力 ， 是 一 种 经 济 断 面 钢 材 ， 广 泛 用 于制 造 石 油 钻 头 ， 例 如 ， 汽 车 传 动 轴 ， 车 架 结 构 件 和 机 械 零 件 ， 钢 铁 建 筑 用 脚 手架 ， 环 的 钢 管 制 造 零 件 ， 可 提 高 材 料 利 用 率 ， 简 化 制 造 工 艺 ， 节 能 ， 如 轴 承 套圈 ， 千 斤 顶 套 等 ， 材 料 和 加 工 工 时 ， 已 被 广 泛 用 于 钢 铁 。 钢 铁 和 各 种 常 规 武 器不 可 缺 少 材 料 ， 桶 ， 桶 就 必 须 使 用 钢 材 。 管 的 横 截 面 积 的 形 状 可 分 为 不 同 的 管和 异 形 管 。 由 于 在 平 等 的 条 件 周 长 ， 圆 的 面 积 最 大 的 钢 管 ， 可 以 携 带 更 多 的 流体 。 此 外 ， 环 截 面 承 受 内 部 或 外 部 径 向 压 力 ， 力 均 匀 ， 因 此 ， 这 是 最 无 缝 钢 管 。不 过 ， 管 也 有 一 些 限 制 ， 如 平 面 弯 曲 的 条 件 下 ， 对 更 好 的 方 管 ， 矩 形 管 抗 弯 强度 ， 一 些 农 用 机 械 框 架 ， 在 钢 铁 和 木 材 家 具 的 常 用 方 ， 矩 形 管 。 为 不 同 目 的 所需 要 的 其 它 形 截 面 型 钢 。无 缝 钢 管 是 用 钢 锭 或 实 心 管 坯 经 穿 孔 制 成 毛 管 ， 然 后 经 热 轧 、 冷 轧 或 冷 拨制 成 。 无 缝 钢 管 的 规 格 用 外 径 *壁 厚 毫 米 数 表 示 。 无 缝 钢 管 分 热 轧 和 冷 轧 （ 拨 ）无 缝 钢 管 两 类 。 热 轧 无 缝 钢 管 分 一 般 钢 管 ， 低 、 中 压 锅 炉 钢 管 ， 高 压 锅 炉钢 管 、 合 金 钢 管 、 不 锈 钢 管 、 石 油 裂 化 管 、 地 质 钢 管 和 其 它 钢 管 等 。 冷 轧（ 拨 ） 无 缝 钢 管 除 分 一 般 钢 管 、 低 中 压 锅 炉 钢 管 、 高 压 锅 炉 钢 管 、 合 金 钢 管 、不 锈 钢 管 、 石 油 裂 化 管 、 其 它 钢 管 外 ， 还 包 括 碳 素 薄 壁 钢 管 、 合 金 薄 壁 钢 管 、不 锈 薄 壁 钢 管 、 异 型 钢 管 。 热 轧 无 缝 管 外 径 一 般 大 于 32mm， 壁 厚 2.5-75mm， 冷 轧 无 缝 钢 管 处 径 可 以 到 6mm， 壁 厚 可 到 0.25mm， 薄 壁 管 外 径 可 到5mm 壁 厚 小 于 0.25mm， 冷 轧 比 热 轧 尺 寸 精 度 高 。无 缝 钢 管 化 学 成 分 中 含 碳 （ C） 量 是 0.420.50%， Si 含 量 为0.170.37%， Mn 含 量 0.500.80%， Cr 含 量 Cr5MoCr9Mo10Cr9Mo1VNb15NiCuMoNb512Cr2MoWVTiBGB5310-1995GB6479-2000GB9948-2006DIN17175-79ASTM SA335ASTM SA213JISG3467-88JISG3458-888-1240*1-200适用于石油、化工、电力、锅炉行业用耐高温、耐低温、耐腐蚀用无缝钢管不锈钢管 0Cr18Ni900Cr19Ni1000Cr25Ni200Cr17Ni12Mo200Cr17Ni14Mo21Cr18Ni9Ti0Cr18Ni10Ti0Cr18Ni11NbGB/T14975-2002GB/T14976-2002GB13296-2007ASTM A213ASTM A269ASTM A312JIS G3459DIN 174586-630*0.5-60适用于石油、航空、冶炼、食品、水利、电力、化工、化学、化纤、医药机械等行业16MnDG、10MnDG、09DGGB/T18984-20038-1240*1-200适用于-45-195级低温29低温管09Mn2VDG、06Ni3MoDGASTM A333Grade1ASTM A333Grade3ASTM A333Grade4ASTM A333Grade6ASTM A333Grade7ASTM A333Grade8ASTM A333Grade9ASTM A333Grade10ASTM A333Grade11ASTM A333 压力容器管道以及低温热交换器管道用无缝钢管高压锅炉管20G ASTM SA106B/CASTM SA210A/CST45.8-III GB5310-1995ASTM SA106ASTM SA210DIN17175-798-1240*1-200适用于制造高压锅炉受热管，集箱，蒸汽管道等高压化肥管102016MnGB6479-2000 8-1240*1-200适用于工作温度为-40-400工作压力为 10-32Mpa 的化工设备及管道石油裂1020GB9948-2006 8-630*1-60用于石油精炼厂的炉管、热交换器管和管道30化管低中压锅炉管10#20#16MnGB3087-2008 8-1240*1-200适用于制造各种结构低压和中压锅炉及机车锅炉输送流体管10#、20#ASTM A106A,B,C、A53A,B16MnGB/T8163-2008ASTM A106ASTM A538-1240*1-200适用于输送流体的一般无缝钢管一般结构管10#、20#、45#、27SiMnASTM A53A,B16MnGB/T8162-2008GB/T17396-1998ASTM A538-1240*1-200适用于一般结构，工程支架、机械加工等石油套管J55、K55、N80、L80C90、C95、P110API SPEC 5CTISO1196060.23-508.00*4.24-16.13油管用于油井中抽取石油或天然气套管用作油气井的井壁管 A、B、X42、X46、X API SPEC 5L 32-1240 用于石油、天31线管52、X56、X60、X65、X70、X80L245、L290、L360、L415、L450GB/T9711.1GB/T9711.2*3-100 然气工业中的氧、水、油输送管直缝钢管20、Q195、Q215A,BQ235A,B、Q345A,B,C,D,EGB/T13793-1992GB3091-200132-630*1-30适用于一般结构支架，低压流体输送等螺旋钢管Q235A-B、Q345A-E SY/T5037-2000 219-2820*4-20适用于低压流体输送用钢管外文资料翻译Mill1 LathesLathes are machine tools designed primarily to do turning, facing and boring, Very 32little turning is done on other types of machine tools, and none can do it with equal facility. Because lathes also can do drilling and reaming, their versatility permits several operations to be done with a single setup of the work piece. Consequently, more lathes of various types are used in manufacturing than any other machine tool.The essential components of a lathe are the bed, headstock assembly, tailstock assembly, and the leads crew and feed rod.The bed is the backbone of a lathe. It usually is made of well normalized or aged gray or nodular cast iron and provides s heavy, rigid frame on which all the other basic components are mounted. Two sets of parallel, longitudinal ways, inner and outer, are contained on the bed, usually on the upper side. Some makers use an inverted V-shape for all four ways, whereas others utilize one inverted V and one flat way in one or both sets, They are precision-machined to assure accuracy of alignment. On most modern lathes the way are surface-hardened to resist wear and abrasion, but precaution should be taken in operating a lathe to assure that the ways are not damaged. Any inaccuracy in them usually means that the accuracy of the entire lathe is destroyed.The headstock is mounted in a foxed position on the inner ways, usually at the left end of the bed. It provides a powered means of rotating the word at various speeds . Essentially, it consists of a hollow spindle, mounted in accurate bearings, and a set of transmission gears-similar to a truck transmissionthrough which the spindle can be rotated at a number of speeds. Most lathes provide from 8 to 18 speeds, usually in a geometric ratio, and on modern lathes all the speeds can be obtained merely by moving from two to four levers. An increasing trend is to provide a continuously variable speed range through electrical or mechanical drives.Because the accuracy of a lathe is greatly dependent on the spindle, it is of heavy construction and mounted in heavy bearings, usually preloaded tapered roller or ball types. The spindle has a hole extending through its length, through which long bar stock can be fed. The size of maximum size of bar stock that can be machined when the material must be fed through spindle.The tailsticd assembly consists, essentially, of three parts. A lower casting fits on the inner ways of the bed and can slide longitudinally thereon, with a means for 33clamping the entire assembly in any desired location, An upper casting fits on the lower one and can be moved transversely upon it, on some type of keyed ways, to permit aligning the assembly is the tailstock quill. This is a hollow steel cylinder, usually about 51 to 76mm(2to 3 inches) in diameter, that can be moved several inches longitudinally in and out of the upper casting by means of a hand wheel and screw.The size of a lathe is designated by two dimensions. The first is known as the swing. This is the maximum diameter of work that can be rotated on a lathe. It is approximately twice the distance between the line connecting the lathe centers and the nearest point on the ways, The second size dimension is the maximum distance between centers. The swing thus indicates the maximum work piece diameter that can be turned in the lathe, while the distance between centers indicates the maximum length of work piece that can be mounted between centers. Engine lathes are the type most frequently used in manufacturing. They are heavy-duty machine tools with all the components described previously and have power drive for all tool movements except on the compound rest. They commonly range in size from 305 to 610 mm(12 to 24 inches)swing and from 610 to 1219 mm(24 to 48 inches) center distances, but swings up to 1270 mm(50 inches) and center distances up to 3658mm(12 feet) are not uncommon. Most have chip pans and a built-in coolant circulating system. Smaller engine lathes-with swings usually not over 330 mm (13 inches ) also are available in bench type, designed for the bed to be mounted on a bench on a bench or cabinet.Although engine lathes are versatile and very useful, because of the time required for changing and setting tools and for making measurements on the work piece, thy are not suitable for quantity production. Often the actual chip-production tine is less than 30% of the total cycle time. In addition, a skilled machinist is required for all the operations, and such persons are costly and often in short supply. However, much of the operators time is consumed by simple, repetitious adjustments and in watching chips being made. Consequently, to reduce or eliminate the amount of skilled labor that is required, turret lathes, screw machines, and other types of semiautomatic and automatic lathes have been highly developed and are widely used in manufacturing.342 Numerical ControlOne of the most fundamental concepts in the area of advanced manufacturing technologies is numerical control (NC). Prior to the advent of NC, all machine tools ere manually operated and controlled. Among the many limitations associated with manual control machine tools, perhaps none is more prominent than the limitation of operator skills. With manual control, the quality of the product is directly related to and limited to the skills of the operator. Numerical control represents the first major step away from human control of machine tools. Numerical control means the control of machine tools and other manufacturing systems through the use of prerecorded, written symbolic instructions. Rather than operating a machine tool, an NC technician writes a program that issues operational instructions to the machine tool. For a machine tool to be numerically controlled, it must be interfaced with a device for accepting and decoding the programmed instructions, known as a reader.Numerical control was developed t o overcome the limitation of human operators, and it has done so. Numerical control machines are more accurate than manually operated machines, they can produce parts more uniformly, they are faster, and the long-run tooling costs are lower. The development of NC led to the development of several other innovations in manufacturing technology: Electrical discharge machining,Laser cutting,Electron beam welding.Numerical control has also made machine tools more versatile than their manually operated predecessors. An NC machine tool can automatically produce a wide of parts, each involving an assortment of widely varied and complex machining processes. Numerical control has allowed manufacturers to undertake the production of products that would not have been feasible from an economic perspective using manually controlled machine tolls and processes.Like so many advanced technologies, NC was born in the laboratories of the Massachusetts Institute of Technology. The concept of NC was developed in the early 1950s with funding provided by the U.S. Air Force. In its earliest stages, NC machines were able to made straight cuts efficiently and effectively. 35However, curved paths were a problem because the machine tool had to be programmed to undertake a series of horizontal and vertical steps to produce a curve. The shorter the straight lines making up the steps, the smoother is the curve, Each line segment in the steps had to be calculated. This problem led to the development in 1959 of the Automatically Programmed Tools (APT) language. This is a special programming language for NC that uses statements similar to English language to define the part geometry, describe the cutting tool configuration, and specify the necessary motions. The development of the APT language was a major step forward in the fur ther development from those used today. The machines had hardwired logic circuits. The instructional programs were written on punched paper, which was later to be replaced by magnetic plastic tape. A tape reader was used to interpret the instructions written on the tape for the machine. Together, all of this represented a giant step forward in the control of machine tools. However, there were a number of problems with NC at this point in its development.A major problem was the fragility of the punched paper tape medium. It was common for the paper tape containing the programmed instructions to break or tear during a machining process. This problem was exacerbated by the fact that each successive time a part was produced on a machine tool, the paper tape carrying the programmed instructions had to be rerun through the reader. If it was necessary to produce 100 copies of a given part, it was also necessary to run the paper tape through the reader 100 separate tines. Fragile paper tapes simply could not withstand the rigors of a shop floor environment and this kind of repeated use.This led to the development of a special magnetic plastic tape. Whe reas the paper carried the programmed instructions as a series of holes punched in the tape, the plastic tape carried the instructions as a series of magnetic dots. The plastic tape was much stronger than the paper tape, which solved the problem of frequent tearing and breakage. However, it still left two other problems. The most important of these was that it was difficult or impossible to change the instructions entered on the tape. To made even the most minor adjustments in a program of instructions, it was necessary to interrupt machining operations and make a new tape. 36It was also still necessary to run the tape through the reader as many times as there were parts to be produced. Fortunately, computer technology became a reality and soon solved the problems of NC associated with punched paper and plastic tape.The development of a concept known as direct numerical control (DNC) solved the paper and plastic tape problems associated with numerical control by simply eliminating tape as the medium for carrying the programmed instructions. In direct numerical control, machine tools are tied, via a data transmission link, to a host computer. Programs for operating the machine tools are stored in the host computer and fed to the machine tool an needed via the data transmission linkage. Direct numerical control represented a major step forward over punched tape and plastic tape. However, it is subject to the same limitations as all technologies that depend on a host computer. When the host computer goes down, the machine tools also experience downtime. This problem led to the development of computer numerical control.3 TurningThe engine lathe, one of the oldest metal removal machines, has a number of useful and highly desirable attributes. Today these lathes are used primarily in small shops where smaller quantities rather than large production runs are encountered.The engine lathe has been replaced in todays production shops by a wide variety of automatic lathes such as automatic of single-point tooling for maximum metal removal, and