• CN: 11-2187/TH
  • ISSN: 0577-6686

Journal of Mechanical Engineering ›› 2022, Vol. 58 ›› Issue (16): 33-42.doi: 10.3901/JME.2022.16.033

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

ZHAO Peng1,2, JI Kaipeng1,2, XIE Jun1,2, ZHUO Chaojie1,2, FU Jianzhong1,2   

  1. 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

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

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