高性能聚合物注射成型构件超声相控阵高效成像方法研究

doi:10.3901/JME.2022.16.033

机械工程学报 ›› 2022, Vol. 58 ›› Issue (16): 33-42.doi: 10.3901/JME.2022.16.033

• 特邀专栏: 高性能塑性成形制造(上) • 上一篇下一篇

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高性能聚合物注射成型构件超声相控阵高效成像方法研究

赵朋^1,2, 纪凯鹏^1,2, 颉俊^1,2, 卓超杰^1,2, 傅建中^1,2

1. 浙江大学流体动力与机电系统国家重点实验室杭州 310027;
2. 浙江大学机械工程学院杭州 310027

收稿日期:2021-11-30 修回日期:2022-05-26 出版日期:2022-08-20 发布日期:2022-11-03
通讯作者: 赵朋(通信作者)，男，1983年出生，博士，教授，博士研究生导师。主要研究方向为聚合物精准成形技术及装备。E-mail：pengzhao@zju.edu.cn
作者简介:纪凯鹏，男，1996年出生，博士研究生。主要研究方向为聚合物超声相控阵检测理论与方法。E-mail：jkp@zju.edu.cn;
颉俊，男，1991年出生，博士后。主要研究方向为抗磁性物质磁悬浮检测理论与方法。E-mail：jxie93@zju.edu.cn;
卓超杰，男，1997年出生，硕士研究生。主要研究方向为聚合物注射成型过程超声在线测量方法。E-mail：zhuocj@zju.edu.cn;
傅建中，男，1968年出生，博士，教授，博士研究生导师。主要研究方向为数控加工、增材制造、智能制造。E-mail：fjz@zju.edu.cn
基金资助:
国家自然科学基金(51875519)、浙江省重点研发计划(2022C01069)、宁波市科技创新2025重大专项(2020Z018)和宁波市企业创新联合体(2021H002)资助项目

Research on Fast Ultrasonic Phased Array Imaging of High-performance Polymer Injection Molded Components

ZHAO Peng^1,2, JI Kaipeng^1,2, XIE Jun^1,2, ZHUO Chaojie^1,2, FU Jianzhong^1,2

1. The State Key Laboratory of Fluid Power and Mechatronic Systems, Zhejiang University, Hangzhou 310027;
2. College of Mechanical Engineering, Zhejiang University, Hangzhou 310027

Received:2021-11-30 Revised:2022-05-26 Online:2022-08-20 Published:2022-11-03

摘要/Abstract

摘要： 注射成型是高性能聚合物构件成形的最主要手段，但高性能聚合物的成形温度高且导热性差，非均匀壁厚构件常因收缩不一致而产生内部缩孔缺陷，显著影响构件性能。提出面向内部缩孔检测的超声相控阵相位偏移高效成像新方法(Fast phase shift migration，FPSM)，将全矩阵数据转换到频率波数域，采用频率与深度方向波数间的映射关系直接计算待测区域的波场，无需耗时的递归计算，并运用爆炸反射成像条件实现高质量成像。仿真试验和实际试验结果表明，与现有3种超声相控阵成像方法相比，FPSM方法显著提高了成像效率，其成像时间在直接测量和楔块辅助测量下分别为相位偏移法的1/30和1/20，并且FPSM方法也具有较高的成像分辨率。同时，高性能聚合物注射成型样条内部缩孔的FPSM成像结果与CT扫描结果基本一致。

关键词: 注射成型, 超声成像, 相控阵, 全矩阵数据, 频率波数域

Abstract: Injection molding is the most important method for molding high-performance polymer components. However, due to the high molding temperature and low thermal conductivity of polymers, the volume ratios at the core and skin of the components during the cooling stage are highly uneven, and the internal voids are easily formed, which greatly affect the mechanical properties of the components. A fast phase shift migration (FPSM) method of ultrasonic phased array full matrix imaging for internal voids detection is firstly proposed in this paper. The method converts the full matrix data to the frequency-wavenumber domain. Then the mapping relationship between frequency and the wavenumber in the depth direction is employed to directly calculate the wave field of the measured region, where the time-consuming recursive calculations are eliminated. Finally, the high-quality imaging result is achieved by the explosion reflection condition. The simulation test and experiment results showed that, compared with the existing three phased array imaging methods, FPSM highly improved the imaging efficiency. In the cases of direct measurement and wedge-assisted measurement, the imaging times of FPSM were only 1/30 and 1/20 of those of the extended phase shift migration, respectively. Besides, FPSM also has advantage of good imaging resolution. In addition, the imaging result of FPSM for the shrinkage voids inside the high-performance polymer injection molded spline was consistent with the CT scan results.

Key words: injection molding, ultrasonic imaging, phased array, full matrix capture, frequency-wavenumber space

中图分类号:

TQ320

赵朋, 纪凯鹏, 颉俊, 卓超杰, 傅建中. 高性能聚合物注射成型构件超声相控阵高效成像方法研究[J]. 机械工程学报, 2022, 58(16): 33-42.

ZHAO Peng, JI Kaipeng, XIE Jun, ZHUO Chaojie, FU Jianzhong. Research on Fast Ultrasonic Phased Array Imaging of High-performance Polymer Injection Molded Components[J]. Journal of Mechanical Engineering, 2022, 58(16): 33-42.

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高性能聚合物注射成型构件超声相控阵高效成像方法研究

Research on Fast Ultrasonic Phased Array Imaging of High-performance Polymer Injection Molded Components

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