Tillämpad matematisk modellering av OFP som stöd vid processtyrning

Transcription

1 Tillämpad matematisk modellering av OFP som stöd vid processtyrning Håkan Wirdelius SCIENTIFIC CENTER OF NON-DESTRUCTIVE TESTING

2 Organisation 2017 Advanced NDT Industrial and Materials Science Integrity and quality assessment by NDE (IqNDE) Ultrasonic and Eddy Current NDE Håkan Wirdelius Gert Persson, Anders Rosell (post doc MSU/GKN) Maria Semenova (PhD) Farham Farhangi (ind. PhD)? Risk Based Quality Assessment Peter Hammersberg SCeNDT Scientific Centre of NDT Project portfolio

3 SCeNDT Research area Applied mathematical modelling of NDE methods Develop and experimental validation of mathematical models of different NDE methods Apply mathematical modelling in the development of NDT as a tool for material characterization (NDC) Use mathematical modelling in the development of new NDT techniques Integrity and quality assessment by NDE (IqNDE) Risk Based Quality Assessment (identification of risks, classification, probability of occurrence and probability of detection) Generate Probability of Detection curves (POD) based on simulated data Education ISI Technologies (graduate and PhD) Education for industry (graduate level)

4 Nondestructive Characterization (NDC) Grain size correlation based on backscattered UT information z y x 5 mm 10 mm l 10 mm Ref. pore = 0.1 mm mm y Ref. pore = 0.1 mm mm z 10 mm x A. Li, R. Roberts, P. Haldipur, F.J. Margetan and R.B. Thompson, Computational Study of Grain Scattering Effects in Ultrasonic Measurements, in Review of Progress in QNDE, (2003). 10 mm

5 The result presentations in the simsundt software The left window from a simulation with grain scattering (39 µm) and the right one without any grain noise.

6 Grain scattering 20 m 39 m 76 m Figure 3: The three B-scans from simulations with different grain sizes (20, 39 and 76 µm) above the reference defect (a sphere with a diameter of 0.2 mm).

7 Backscattered amplitude (linear), 8 MHz (75%)

8 Conclusions Conclusions Clear correlation between backscattered amplitude and grain size The correlation is autonomous, i.e. not depending on the specific distribution of grains and/or stiffness distribution There is a correlation between backscattered amplitude and stiffness but of less order If the procedure is based on frequency content then the mean value of a number of measurements would be required

9 Normalization of the frequency content based on the second pulse 20 µm The frequency content of the normalized pulse (A 1 (f)/t- A 2 (f)/3t) and corresponding (KIMAB) for one single grain size to the left.

10 IqNDE in manufacturing industries Non-destructive Quality Assessment based on hybrid modelling Today: empirical based model is used in order to define a go/no go value Today: time consuming destructive examinations Today: amplitude, time of flight, frequency and phase information (UT) are reduced down to a binary information Proposed project: Project: meta-models to combine experimental with corresponding simulated data Project: dynamically built meta-model (AI) Project: continues assessment of quality related material parameters Project: can be combined with process parameters and contribute to deeper understanding of process variations

11 IqNDE in manufacturing industries Non-destructive Quality Assessment based on hybrid modelling Let be the addressed material property and d be the signal response (NDT) with assumed correlation Empirical based model in order assess uniformity of the production quality = (d) Acceptance criteria based on assumed uncertainties due to used measurement techniques and in the empirical model as such Very static and a change in the production process a new empirical model must be developed empirical d accept time

12 IqNDE in manufacturing industries Non-destructive Quality Assessment based on hybrid modelling If an analytical model would be used as a calibration tool The deviation between existing mathematical models and corresponding non-destructive techniques is still insufficiently large (idealized states: isotropic, homogeneous, high frequency, ) Discretization based models are still very time consuming and therefore not applicable in larger parametric studies or in an in-line situation Probably a wider tolerance than a gate based on an empirical model of the correlation d analytical accept/empirical accept time

13 IqNDE in manufacturing industries Non-destructive Quality Assessment based on hybrid modelling A dynamic meta-model that combines experimental data with corresponding simulated data More efficiently provide with go/no go information in the initial stage A model that collects quantitative information of produced components continuously The developed meta-models can then also contribute to deeper understanding of process variations d semi-analytical accept

14 IqNDE in manufacturing industries Non-destructive Quality Assessment based on hybrid modelling Analytical model: d m (, x 1... x k ) Semi-analytical model: d analytical empirical semi-analytical production cycles