轧辊检测

1©2009InnseCilindri–AllRightsReservedRollInspection轧辊的检验Feb.200909年2月2©2009InnseCilindri–AllRightsReservedROLLINSPECTIONMETHODS轧辊检验的方法MANUALSYSTEMS手动系统AUTOMATICSYSTEMS自动系统3©2009InnseCilindri–AllRightsReservedVISUALINSPECTION视觉检查[V]Theoldestandmostcommonsystemtorecognizeawidevarietyofdefects能识别各种各样的缺陷的最古老又最常用的系统ThefirststepinrollsurfaceproblemsDetermination决定辊面问题的第一步ROLLINSPECTIONMETHODS轧辊检验方法4©2009InnseCilindri–AllRightsReservedMAGNETICPARTICLE磁粉法[MP]ADVANTAGES优点•usefulfordetectinganysurfacedefects对检测任何表面缺陷是有用的•inexpensiveandeasytouse价格便宜，易于使用•fasterthandyepenetranttesting快于染料渗透检测DISADVANTAGES缺点•usefulonferromagneticmaterials仅对铁磁材料有用•limitedtosurfaceandclosetosurfacediscontinuities限于表面和近表面的不连续性的检测Cracks裂纹ROLLINSPECTIONMETHODS轧辊检验方法5©2009InnseCilindri–AllRightsReservedDYEPENETRANT染料渗透法[DP]ADVANTAGES优点•excellentindetectingsurfacebreakingdefects对表面损坏缺陷检测极有用•notexpensiveandsimpletodo不贵，操作简单•nopowerrequired没有电力要求DISADVANTAGES缺点•detectonlysurfacediscontinuities只能检测表面的不连续性•timerequired(30–40min)所需时间较长（30-40分钟）•surfacemustbecleananddry表面必须清洁干燥Cracks裂纹ROLLINSPECTIONMETHODS轧辊检验方法6©2009InnseCilindri–AllRightsReservedEDDYCURRENTSYSTEM涡流测试系统[EC]ADVANTAGES优点•excellentindetectingsurfacedamages表面损伤检测极有用•usefultoindicatestructuralvariationsonsurface对揭示表面结构变化有用•easilyautomated轻松自动化•highspeedcontrol(100%rollbarrelsurface)高速控制（100％辊表面）DISADVANTAGES缺点•detectonlyconductivematerials只能检测导电材料•manyvariablesinfluncethesignal许多变数会影响信号•reduceddepthofpenetration探测深度较少ROLLINSPECTIONMETHODS轧辊检验方法7©2009InnseCilindri–AllRightsReservedCrackIdentification裂纹识别ECtestdoesnotmeasuredirectlycrackdepth涡流测试不直接测量裂纹深度ECtestcannotdistinguishcrackorientation该测试不能区分裂纹方向ROLLINSPECTIONMETHODS轧辊检验方法EDDYCURRENTSYSTEM涡流测试系统[EC]8©2009InnseCilindri–AllRightsReservedBruiseIdentification挫伤鉴定(structuralalteredzone)（构造蚀变带）Usuallyconcernspotsorlocalizedareas通常关注的是点或局部地区Suitablefiltersystemallowstodistinguishthesestructuralanomaliesfromcracks合适的过滤系统可以将这些结构异常同裂缝区分开ROLLINSPECTIONMETHODS轧辊检验方法EDDYCURRENTSYSTEM涡流测试系统[EC]9©2009InnseCilindri–AllRightsReservedSystemsetuprequireshighdegreeofskillandalotoftraining系统建立则需要高度的技巧和大量的培训ECSystemissensitivitytomanyparameters涡流系统对许多参数都敏感ROLLINSPECTIONMETHODS轧辊检验方法EDDYCURRENTSYSTEM涡流测试系统[EC]10©2009InnseCilindri–AllRightsReservedULTRASONICSYSTEM超声系统[UT](manualsystem人工系统)ADVANTAGES优点•penetratetoconsiderabledepths渗透到相当的深度•usefultosurveyslightdefects对略有缺陷的调查是有用的•capabletodeterminatesizeanddepthofdefects能够确定缺陷的规模和深度•easilyautomated轻松地做到自动化DISADVANTAGES缺点•trainedoperatorsrequired要求有受过训练的操作人员•signalinterpretationmaybeverydifficult信号解释可能是非常困难的ROLLINSPECTIONMETHODS轧辊检验方法11©2009InnseCilindri–AllRightsReservedInspectionpurposes:检查目的：1.detectionofinternaldefects内部缺陷检测2.detectionofrolling-inducedsurfacecracks检测轧制诱导的表面裂纹ROLLINSPECTIONMETHODS轧辊检验方法ULTRASONICSYSTEM超声系统[UT](manualsystem人工系统)12©2009InnseCilindri–AllRightsReservedInternaldefects内部缺陷IDENTIFICATION识别MONITORINGduringSERVICE监控服务PROBE探针2.0MHz(d=25mm)singleelement单相LONGITUDINALWAVES纵波ROLLINSPECTIONMETHODS轧辊检验方法ULTRASONICSYSTEM超声系统[UT](manualsystem人工系统)13©2009InnseCilindri–AllRightsReservedSurfaceorinternalcracks表面或内部裂缝PROBES探针SURFACEWAVES(90degrees)面波（90度）SHEARWAVES(2MHz–45/60/70degrees)横波（2兆赫-45/60/70度）LONGITUDINALWAVES(5MHz)纵波（5兆赫）LONGITUDINALWAVES(4MHz–dualelement)纵波（4MHz-双元）ROLLINSPECTIONMETHODS轧辊检验方法ULTRASONICSYSTEM超声系统[UT](manualsystem人工系统)IDENTIFICATION识别MONITORINGduringSERVICE监控服务14©2009InnseCilindri–AllRightsReservedSHELL工作层CORE辊芯DISBOND结合不良CRACK裂纹STRAIGHTBEAM直射束SURFACEWAVE面波ANGLEBEAM斜束DUALELEMENT双元2MHz5MHz70°2MHz45°2MHz4MHzROLLINSPECTIONMETHODS轧辊检验方法ULTRASONICSYSTEM超声系统[UT](manualsystem人工系统)15©2009InnseCilindri–AllRightsReservedUT+ECCOMBINEDSYSTEM(automaticsystem)超声+涡流复合系统（自动装置）Automatic自动化的Fullyintegratedingrindingpractice与修磨操作完全集成Keeptogetherthebenefitsof2technique保持这两个技术的优点OPTIMALMAINTENANCEofROLLS优化轧辊的检修PREVENTIONofCATASTROPHICROLLFAILURES防止灾难性轧辊故障COSTSAVINGS节省开支ROLLINSPECTIONMETHODS轧辊检验方法16©2009InnseCilindri–AllRightsReservedInspectionResults检查结果–DisplayData显示数据Cracks/Bruise裂缝/损伤LOCALIZATION局部化CSCANVIEW扫描图A3DVIEW3D视图ROLLINSPECTIONMETHODS轧辊检验方法UT+ECCOMBINEDSYSTEM(automaticsystem)超声+涡流复合系统（自动装置）17©2009InnseCilindri–AllRightsReservedC–SCANVIEW扫描视图EXAMPLE1–4HiReversingStand示例1–4辊可逆式机架A–FIRECRACKS热裂纹B–CRACKS裂纹(VERYDEEP很深)(automaticsystem自动装置)ROLLINSPECTIONMETHODS轧辊检验方法18©2009InnseCilindri–AllRightsReservedA–SCAN扫描PROBLEMAREAA问题区域AECresults:EC结果：typicalfirecracksNetwork典型热裂纹网络ROLLINSPECTIONMETHODS轧辊检验方法(automaticsystem自动装置)19©2009InnseCilindri–AllRightsReservedPROBLEMAREAB–SEVERALSURFACECRACKS问题B区-几种表面裂纹SURFACEASPECT表面外观PROPAGATION扩散ROLLINSPECTIONMETHODS轧辊检验方法20©2009InnseCilindri–AllRightsReservedUTresults:UT结果：Cracks裂纹(30-50mmindepth)（30-50毫米的深）ROLLINSPECTIONMETHODS轧辊检验方法(automaticsystem自动装置)21©2009InnseCilindri–AllRightsReservedEXAMPLE2–LastFinishingStands示例2-末端精轧机架30mmDEEP30毫米深50mmSPALLING剥落ROLLINSPECTIONMETHODS轧辊检验方法22©2009InnseCilindri–AllRightsReservedUTresultsUT结果ROLLINSPECTIONMETHODS轧辊检验方法(automaticsystem自动装置)23©2009InnseCilindri–AllRightsReservedECresultsafterprevioust