Research on Dynamic Detection of Rail Rolling Contact Fatigue Crack Based on Eddy Current Thermography

doi:10.3901/JME.2021.18.086

Abstract

Abstract: In response to the challenge of rail rolling contact fatigue crack detection, a multi-physics eddy current thermography technology under new sensor structures is proposed. Through COMSOL Multiphysics finite element simulation software, the electromagnetic field characteristics of the cylindrical magnetic core structure, the arc-shaped yoke structure and the U-shaped yoke structure are analysed, and the detection effect of fatigue crack under different sensing architectures is studied. According to actual application conditions, the L-shaped yoke and the shuttle-shaped yoke structures are developed based on the U-shaped yoke structure, and the induction excitation source system is integrated and developed. Defect detection experiment of milled rail test blocks in the static state shows that the self-developed system has high detection sensitivity for small defects on the rail surface. It can realize quantitative analysis of 0.5 mm wide defects and identify defects with a minimum width of 0.2 mm on the rail surface. Through the defect detection experiment of disc, the fatigue crack detection under speed effect is studied. The proposed robust low-rank tensor crack decomposition algorithm greatly eliminates the background noise of the original thermal image and improves the defect detection resolution. Finally, the low-speed rail inspection experimental platform is built and integrated to verify effectiveness of complex rolling contact fatigue crack detection on rail treads.

Key words: rolling contact fatigue crack, eddy current thermography, sensor architecture, quantitative detection, low-speed inspection

CLC Number:

TG156

MIAO Ling, GAO Bin, SHI Yongsheng, LI Haoran, LI Xiaofeng, WU Tongle, ZHANG Xiyuan, TIAN Guiyun. Research on Dynamic Detection of Rail Rolling Contact Fatigue Crack Based on Eddy Current Thermography[J]. Journal of Mechanical Engineering, 2021, 57(18): 86-97.

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