Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Ingolf Hertlin
President
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
Contents
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Fig. 1: Time signal (left) and resonant frequencies after impact (right)
pass / OK
cracked
material structure
hardness deviation / partly hardened
A technical bulletin describing prerequisites, influencing factors, test parameters and reliability is
available from RTE. Please contact us.
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
1.
2.
Dimension
A dimensional variation, e. g. wall thickness, changes the stiffness of the part and
has an influence which often only affects certain resonances. It is important to find
out which are sensitive and which are not.
Compensation requires to systematically identify which resonances are affected and
which are not. If possible a workpiece with maximum size is mechanically processed
to the allowed minimum value. Another method is to use a FEM and to calculate the
vibration modes at maximum and minim um value.
3.
Weight
Parts with weight differences which do not result from a dimensional variation or material structure (density variation in powder metal) have lunker or porosity. This also
changes the resonant spectrum, but this influence is often not evident. The influence
on the spectrum is non-linear and requires special compensation methods.
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49 (0)721/94650-0 Fax -50 www.rte.de info@rte.de
Table of Contents
1
Introduction ..............................................................................................................................2
Analysis ....................................................................................................................................3
Measurements .........................................................................................................................3
4.1
4.2
Date
Author
26.11.2009 Legler, Hertlin
Description
RTE METH Damping and Quality Brake Disks E-100518
100518
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. 0721/94650-0 Fax 0721/94650-50 www.rte.de info@rte.de
Introduction
Recording the vibration mode parameters is becoming increasingly important in brake disk
test ing. Besides determining the natural frequencies, we also have to assess the damping
that will enter as quality Q in the quality evaluation.
In cooperation with Daimler AG, RTE has developed and implemented
implemented an appropriate method, de scribed in the following.
Measurement Principle
Messmikrofon
Measuring
microphone
Specimen
Prfling
Impulse hammer
Impulshammer
Once recorded, the resonance response is available as information in digital form and can be
used for the analysis. In an initial approximation, the Fourier (spectral) analysis of the re corded signal shows which resonant frequencies are present. The damping and the r esulting
quality Q may be regarded as a measure of the speed at which the resonant fr equency dies
down. The faster this happens, the lower the quality Q.
Figure 2 : The output signal (left) and the spectral analysis (right)
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. 0721/94650-0 Fax 0721/94650-50 www.rte.de info@rte.de
Analysis
Actually, the aforementioned methods are only conditionally suited for determining the nat ural frequencies and quality with the desired precision. In its procedure RTE relies on the circular approximation already used in the vibrational mode analysis. Here the information is
represented not as a spectrum, but as a frequency response locus, and the vibration mode
variables of the reso nant frequency and the quality are derived.
The Fourier analysis of a signal yields two s equences
of data, referred to as an "imaginary part" and "real
part," respectively. If we now plot this imaginary part
against the real part, we obtain, instead of a reso nance, circles or circular segments by means of which
we can determine the vibration mode variables.
By interpolating on the basis of multiple measu ring
points we can determine these variables with high accuracy.
Figure 3 : The determination of the vibration mode variables through circular approximation of a dampened vibr ation
This method reveals its strength particularly with resonances lying close to one another or in
the case of double lines, since the parameters can be determined with sufficient prec ision
even in a one-sided approximation (i.e. from the unaffected end).
Measurements
4.1
The determination of the resonant frequencies is quite simple, since they occur at nearly all
points of the disk and can be easily recorded with the integral measuring microphone. One to
two excitations in the vicinity of the outside diameter generally suffice. The occurrence of
dou ble lines shall be considered insofar as, depending on the location of the excitation or
measurement, the lower, the upper or even both lines will have to be measured, making
slight shifts in the results possible. This variation is generally low relative to the test tolerance
stated in the EKB 200 2, however.
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. 0721/94650-0 Fax 0721/94650-50 www.rte.de info@rte.de
4.2
A reproducible determination of quality requires that the resonant frequencies be dete rmined
with high precision in the method mentioned in section 3.
The determination of the quality Q shall consider the following properties:
1.) The quality depends on the vibration mode, i.e. it does not suffice to derive the qu ality
from the overall attenuation process. Like the resonant frequencies, the parameters for
the quality shall be treated s eparated from the individual modes.
2.) The mode-specific damping and consequently the quality depends on the measurement
location. Of interest is the minimum quality or the maximum damping.
3.) It shall be specified which modes must be considered, since the
t he number of excitation
segments will depend on this. In principle no limitation is imposed by the measuring
technology or the method.
Excitation / measurement
Measur ing along the circumferential direction yields mode-dependent fluctuations for the
quality that are repeated as a function of the angle.
Depending on the mode and given the number of modes to be determined, we obtain a me asurement profile composed from a series
series of single measurements at a certain angle relative
to one another.
RTE reduces the number of measurements to a minimum, so that such a test can also be
em ployed in production with the pace maintained. Positioning units are controlled by the test
sof tware so that during the test the disk is rotated according to the measuring program d esigned for the specific task. An impacting unit and the corresponding measuring microphone
suffice for conduct ing this test fast and reliably. Suitable test apparatuses for manual as well
as for fully automatic operation are avai lable.
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. 0721/94650-0 Fax 0721/94650-50 www.rte.de info@rte.de
Volume testing
Non-destructive
Sensitivity
Speed
Automation capability
Defect assignment
Limitations, prerequisites
Surface defects
Structure
Reference objects
Defect size
Defect location
A technical bulletin describing prerequisites, influencing factors, test parameters and reliability is
available from RTE. Please contact us.
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
Prerequisites
The fault influences the components vibration behaviour in a measurable way. Other
faults will not be detected by ART.
Verification of
suitability
Influencing
factors
Test objects are subject to influences which may or may not be relevant for quality
and which change the positioning of resonance frequencies. Some influencing
factors such as temperature and dimension can be compensated for if necessary.
Fluctuations in such influencing factors, of the basic raw material (batch), of the
components or of processing makes adapting the test parameters or the setting up
of additional test parameters necessary.
Test
parameters
Reliability
Additional
documents
Updated: 3/2010
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
bearings
NVH
SonicTC.Castings
material
SonicTC.Composites
material
SonicTC.Drives
NVH
SonicTC.EigenFrequency
material
SonicTC.Engines
combustion engines
NVH
SonicTC.Fans
exhauster, ventilator
NVH
SonicTC.FineCeramics
material
SonicTC.Gearboxes
NVH
SonicTC.Gears
material
SonicTC.HeayClay
material
SonicTC.MetalForming
deep-drawing, thermoforming
material
SonicTC.PowderMetal
sintered parts
material
SonicTC.Pumps
NVH
SonicTC.Seats
NVH
SonicTC.Tools
driven units
NVH
SonicTC.Turbines
turbines
NVH
SonicTC.Universal
both
SonicTC.Welding
material
SonicTC.WhiteGoods
household devices
NVH
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
Characteristics
SonicTC.EigenFrequency conforms to the
above requirements, offers an excellent
price/performance ratio and records your frequencies quickly and simply. The design of the
measuring chamber was acoustically optimized
for such measurements and meets Employers'
Liability Insurance Association regulations. The
control and evaluation unit with the 17 touch
panel displays the natural frequencies to the user within seconds and monitors them relative to
settable limits.
SonicTC.EigenFrequency offers automatic multi-position measurements and can thus guarantee
high reliability. As the micro structure of cast parts can change, the system also takes into account
the age of the specimen at the time of measurement.
SonicTC.EigenFrequency is of robust construction and can be used in severe industrial environment. The equipment can also be changed over quickly from one kind of component to another in
a few steps. In the laboratory, the SonicTC.EigenFrequency offers a variety of additional archiving
and analysis options that can provide useful information for the developer.
Benefits
Excellent price/performance ratio
Can be used on different products with minimal change-over
Permits compliance with customer specifications with minimum effort
Modular design makes equipment a sound investment
Reliable multi-position measurements of natural frequency values and ageing compensation
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
Device variants
Frequency range
o Power spectrum
o User-adjustable frequency bands
Data acquisition
Multiple excitation
24-bit resolution
51.200 samples/second
Expandabilit y
Fixtures for brake anchors, housings, brake discs, brake drums and others
Temperature compensation
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
Measurement
Methods
(selection)
Software
Hardware
Operation modes
Performance
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal / Germany Tel. +49 721/94650-0 Fax: -50 www.rte.de info@rte.de
RESONANCE ANALYSIS
The newcomer in
non-destructive material testing
Every day people and machines all over the world are testing millions of products before they are used e.g. in vehicles and machines. These tests are absolutely necessary to guarantee that the
products are faultless and do not cause any damage when in use or
even endanger life. It is usually people who have to carry out the tests and within a very short
time have to make subjective decisions about quality characteristics which they cannot judge or
can judge only inadequately by assessing the surface. Interior errors such as cracks, cavities
and structural variations are important quality characteristics which cannot be detected on the
surface. In addition, the most frequently used non-destructive test procedures such as x-ray,
magnetic powder or dye penetrant inspection are expensive, elaborate and damaging to the environment.
Characteristics
Different versions of SONIC|TC are available for different branches of industry such as foundries, coarse or
fine ceramics, powder metal or metal forming
processes.
SONIC|TC.Universal has been assembled for the laboratory, research and higher education area. Here you
receive the complete range of functions for making use
of all possibilities in tests. For a routine test you can
then scale down to just the functions required.
Mode of operation
The component is either made to vibrate manually or electromechanically by tapping. A microphone records the sound of the component and directs it for processing to the computer.
SONIC|TC has a multitude of procedures available for analyzing and evaluating the sound.
Functions such as a post-evaluation for carrying out the what if consideration due to signals
recorded, a reference run for adapting the parameters to e.g. batch influences or various compensation procedures for balancing influences on temperature or weight complete the comprehensive software package.
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal (Germany) Phone +49 721/94650-0 Fax +49 721/94650-50 www.rte.de info@rte.de
RESONANCE ANALYSIS
The newcomer in
non-destructive material testing
Here the effect of frequency
shift as an assessment criterion is illustrated. Due to
the defect, the propagation
of the vibration is impaired,
it differs from the normal
routine image. The position
of individual resonances is
monitored and assessed.
If an FEM analysis of the component is also available, then an allocation of the resonances and thus of the fault too can be made
to certain component areas. The FEM analysis is useful in understanding the vibration behavior of the component and gives indications concerning the ideal site for stimulation and the optimal hold
positions.
Your advantage
Profit from an innovative and environmentally friendly technology - no pollution by chemicals or
radiation, no expendable materials. The requirements for a laboratory measurement are few.
Very good results can be achieved even with simple resources. Thus the technology is also excellently suited for practical laboratory exercises.
On the other hand, there are still many effects for which there is still no mathematical description. Or we measure acoustic effects for which we have no explanation. The smaller the test
objects, the more problematic the stimulation of the components becomes. So for many research areas there are still excellent topics for a thesis or dissertation.
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal (Germany) Phone +49 721/94650-0 Fax +49 721/94650-50 www.rte.de info@rte.de
RESONANCE ANALYSIS
The newcomer in
non-destructive material testing
Users
RTE maintains good contacts with higher education colleges and institutes in the region and
has also expanded internationally in the past years. The following institutions use our systems
in lectures, laboratories and in research (selection):
University of Miskolc
Hungary
Czech Republic
Karlsruhe
Cologne
Fraunhofer IZFP
Saarbrcken
Potsdam
Karlsruhe
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal (Germany) Phone +49 721/94650-0 Fax +49 721/94650-50 www.rte.de info@rte.de
RESONANCE ANALYSIS
The newcomer in
non-destructive material testing
Who are we?
RTE Akustik + Prftechnik GmbH (Acoustic + Testing Technology) was
founded in 1986 as a technology-oriented company with the objective of providing products and services in the area of acoustic testing technology.
RTE counts amongst its customers chiefly firms in the automotive industry,
foundries, forges, in housing and medical technology or in the ceramics industry.
Our customers can profit from our 25 years experience.
RTE supplies acoustic measuring and testing technology for production in
the areas
Services
Service and Support (24/7), feasibility analyses, design service, training
Address
RTE Akustik + Prftechnik GmbH
Gewerbestr. 26
D-76327 Pfinztal
Phone: +49 (0)7 21 9 46 50-0
Fax:
+49 (0)7 21 9 46 50-50
info rte.de
www.rte.de
www.rte-acoustics.com
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal (Germany) Phone +49 721/94650-0 Fax +49 721/94650-50 www.rte.de info@rte.de
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49 721/94650-0 Fax -50 www.rte.de info@rte.de
Partners worldwide
Country
RTE area
Company
Internet
Brasil
Material testing
RAIMECK Ltda
Sao Paulo
www.raimeck.com.br
China
Material testing
www.dehua.com.hk
India
Material testing
www.ndttechnologies.co
m
Iran
Material testing
www.hami-yekta.com
France
Noise testing
Material testing
Vibration testing
www.rte.de
Austria
Material testing
Mittli KG
Wien
www.mittli.at
Indonesia
Material testing
Panairsan
Jarkata
www.panairsan.com
Mexico
Noise testing
Material testing
Vibration testing
www.grupoctt.com.mx
Korea
Material testing
Croatia
Material testing
IDEF d.o.o.
Zagreb
www.idef.hr
Slovenia
Noise testing
Material testing
Vibration testing
www.team-trade.si
Turkey
Material testing
www.tmmndt.com
Czech
Republic
Material testing
www.testima.cz
Spain
Material testing
Vibration testing
EUROMAQUINA S.A.
Madrid
www.euromaquina.com
Taiwan
Material testing
www.ai-kwang.com.tw
Thailand
Material testing
www.ndtithai.com
Venezuela
Material testing
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
It is necessary to understand the preconditions, which permit successful application of the very powerful acoustic methods. We need to analyse the way in which a perfect specimen differs from a faulty one. The
type of defect must also be established, as unambiguously as possible.
RTE can examine test pieces in its own lab or directly on the customers premises. RTE offers its customers different levels of service:
Service level 0:
Quick look
Service level 1:
Product evaluation
Typical test samples of the same batch are analysed in RTEs lab
(number has to be agreed - typically 10 perfect samples and some
faulty ones per typical defect) to analyse the typical differences between good and bad parts. This includes reproducibility, excitation and
sensor position and characteristics for the classification.
We charge our customers at a flat rate for equipment and documentation which includes the investigations results in the form of a comprehensive report. Please ask for an offer.
The results obtained at this level will be of direct benefit during the following collaborative stages.
Service level 2:
Process evaluation
(measuring on site)
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
Customer:
Drawn up by:
Place:
Date:
Acoustic resonance testing (ART) is, like ultrasonic, a volume-related method with which flaws can be
recognized in the work piece (in contrast to the surface-related method such as magnetic particle testing or
eddy current). It is likewise a comparative method: the characteristics are compared with those of good parts.
With a Quick look (QL) it should be possible to test whether ART is in principle applicable to recognize the faulty
parts according to the customer's requirements. The Product evaluation with more parts follows if the QL is positive.
1. Product description
No.
Questions
P 1 Name of the product
P 2 What kind of material is being dealt with?
(elastic-modulus, density, basic material etc.)
P 3 In which area is the product used?
(e.g. brake system, gears)
P 4 Number of variations / types?
P 5 Processing condition of the parts?
(e.g. stripped, blasted, ground, finished condition,...)
P 6 Error description
(e.g. crack, difference in hardness, porosity, nodularity)
P 7 Cause of error
(by the processing machine, from the raw material...)
Description
2. Selection
No.
General
Number:
to
be
agreed
(QL:
3 OK, up to 3 NOK)
S1
S 2 Marking: clear marking imperative!
S 3 Batch: according to S1 all from one batch!
S 4 State of processing:
S 5 Results / information from other test procedures?
(Manufacturer / method)
Remarks
Specimen should only differ according to the
defect
NOK parts with faulty section marked
Comparative method!
If not possible: mark batch parts accordingly
all in the same condition (comparative method!)
Description
4. Customer data
No.
C1
C2
C3
C4
C5
C6
Questions
Analysis report: to whom?
Contact partner for RTE (responsible for project)?
What happens to tested objects? (freight collect or scrap?)
Responsible for production planning?
Responsible for investment decision?
In-line testing planned? (Manual loading / unloading or fully
automatic?)
C 7 Urgency for in-line testing?
C 8 Cost expectation for overall solution?
Description
Subject
Customer:
City:
Author:
Date:
Result
Comment
Aim of testing
Current status / testing
Is a test specification available?
Test object
Description
(TO)
We appreciate photos!
Description of defects
We appreciate photos!
Cycle time
Part feeding (manual, automatic)
Part storing (manual, automatic)
Handling time
Type of production control (PLC)
Marking/labeling of parts after test?
Test conditions
Operation
noise:
temperature:
humidity:
dust, dirtiness:
Design
Mechanics:
Electric:
Pneumatic:
offline/online
language:
number:
complexity:
Contact
person
Production
Quality management
Purchase
Project ma-
nagement
Payment terms:
advance payment
delivery
installation
acceptance
Stand: 06/02
Application Areas of
Acoustic Resonance Testing
Acoustic resonance testing can be applied to all workpieces that sound.
Industry
Casting
Ceramics
Die-casting
Material
Products (examples)
Testing for
iron casting
grey casting
strut plate
cracks, structure
clay
catalytic converter
cracks
cracks
Aluminium
cracks
synchronous rings
cracks
bottles
cracks
plates
cracks
Ingot mould
cracks, inclusions
Metal forming
cracks (smilies)
cracks
miscellaneous products
cracks
planetary carrier
cracks, welding
drive shafts
steering racks
cracks, hardness
rims
cracks
Glas
Sintered metal
Steel
powder metal
iron
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
Solution
Benefit
Testing Technology
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Karlsruhe Tel. 0721/94650-0 Fax 0721/94650-50 www.rte.de info@rte.de
Solution
Benefit
Testing Technology
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Karlsruhe Tel. 0721/94650-0 Fax 0721/94650-50 www.rte.de info@rte.de
Application Note
Natural frequency measurement of brake
discs for production and laboratory
Task
The natural frequency of a vibrating system is that at which it will vibrate after a nonrecurring
excitation. If a system is subjected to external excitation at a frequency coincident with its
natural frequency, the system will vibrate with particularly large amplitude, which is known as
resonance. Requirements for brake discs are defined in the EKB 2002 Technical Standard
by the European Brake Noise Experts Group, which is supported by OEMs like Daimler, Audi, VW, Fiat, BMW, Ford and Porsche and all main component manufacturers have to adhere.
Characteristics
SonicTC.EigenFrequency from RTE conforms to the above requirements, offers an excellent price/performance ratio and records your frequencies quickly and simply.
SonicTC.EigenFrequency offers automatic multi-position measurements and can thus guarantee high reliability. As the micro structure of cast parts can change, the system also takes
into account the age of the specimen at the time of measurement.
SonicTC.EigenFrequency is of robust construction and can be used in severe industrial environment. The equipment can also be changed over quickly from one kind of component to
another in a few steps. In the laboratory, the SonicTC.EigenFrequency offers a variety of
additional archiving and analysis options that can provide useful information for the developer.
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
Solution
Benefit
Testing Technology
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Karlsruhe Tel. 0721/94650-0 Fax 0721/94650-50 www.rte.de info@rte.de
Solution
Benefit
Testing Technology
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Karlsruhe Tel. 0721/94650-0 Fax 0721/94650-50 www.rte.de info@rte.de
Solution
Type identification by camera (dot matrix code) and automatic adaption of sensors and actors by servo-motors
Benefit
Testing Technology
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Karlsruhe Tel. 0721/94650-0 Fax 0721/94650-50 www.rte.de info@rte.de
Solution
Benefit
Testing Technology
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Karlsruhe Tel. 0721/94650-0 Fax 0721/94650-50 www.rte.de info@rte.de
Brake discs:
Semi-automatic natural frequency testing
Brake discs:
Fully automatic natural frequency testing
CD EF Videos E-120411
Order:
copies
Fa.
Company:
Name, first name:
Street:
ZIP code, city:
Country:
Tel.:
Fax:
E-Mail:
Member of DGZfP e.V.
DGaQs e.V.
Place, date
Signature
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
F2
F3
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
F4
The excitation has to stimulate the test specimen to vibrate in its resonances.
These can then be measured by a microphone, a laser vibrometer or an accelerometer (see F 5).
The impulse modal hammer consists of a quartz force sensor mounted on the
striking end of the hammer head to measure the excitation force. As the excitation force has only an influence on the resonance frequency amplitude, but not
on the value, it is not necessary to use a modal hammer for resonance frequency evaluation.
An electrodynamic hammer is designed to have a short contact time, can be
adjusted to the necessary excitation force and allows constant amplitudes. This
device is sufficient for natural frequency testing and used in automation applications.
Manual excitation is used in initial tests. As the excitation force is not constant
the level of the resonances varies.
Piezo-electric actors vibrate at a specific frequency depending on the supplied
voltage. When you contact such a device with the test specimen it will vibrate
with the same frequency as the actor. If the actor frequency meets a resonance
frequency of the part you can measure this with a second sensor (accelerometer). The advantage is the high frequency range, the disadvantage is that it is
necessary to sweep the induced frequencies. This is time consuming and the
contact quality and position have a great influence on the result.
F5
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
position the microphone is the only device that can measure integral, i.e. all
frequencies regardless of the position. To measure all vibration modes with
significant amplitude two or more microphones can be used.
F6
F7
F8
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
The reference values in a drawing are referred to 'aged' parts. A very theoretical solution would be to wait 30 days before performing the measurement. The more efficient way is to input the age of the part into the mea surement software which uses this information to calculate the values as
they would be at an age of 30 days.
All types of compensation methods mentioned above are part of RTE's
test software SonicTC.EigenFrequency.
F9
Yes - as long as the measurement conditions follow the rules mentioned above.
It can be used for low volume/laboratory (Fig. 5), optimized for brake discs),
medium volumes in labs/shop floors (Fig. 6) and manufacture integrated as fully automated units (Fig. 7, Fig. 8).
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
Yes - there are some. Common specifications concerning brake parts are the
EKB Technical Standards from the European Brake Noise Experts Group (EKB
2001/2002 for brake discs, EKB 4001 for brake calipers). It contains some hints
regarding theory and practical application of that test. In addition the brake
manufacturers and OEMs often have proprietary specifications.
RTE Akustik + Prftechnik GmbH Gewerbestr. 26 D-76327 Pfinztal/Germany Tel. +49/721/94650-0 Fax +49/721/94650-50 www.rte.de info@rte.de
Abstract
Cracks, porosity and density differences can occur during the manufacturing process.
The non-destructive testing method acoustic resonance testing (ART) allows fast
quality control of each single part integrated in the production flow. The method
evaluates in particular the mechanical stiffness of the test specimen. The temperature
of the part, dimensional variations and mass / density variations have an influence on
the measurement results (resonant frequencies) in the same way as cracks and
porosity and may mask them. Compensation methods allow the - permitted - productspecific variations to be distinguished from defects. In this way the method is able to
detect capillary cracks reliably. The presentation describes the procedural method, the
type and nature of compensation and the results of industrial applications.
Keywords
Non-destructive testing (NDT), quality control, acoustic, resonance analysis, crack
testing, process compensation, acoustic resonance testing
Introduction
Acoustic sound analysis is a well-established non-destructive method for components
that radiate sound, especially in metal and ceramic industry. The method is used in
high-volume production to scan the parts fast and cost-effective within the production
flow.
Not only the raw materials, but also the manufacturing process affects the product
characteristics and determines how a specimen sounds. Whereas human testers can
easily adapt to this, an automatic inspection system relies on references and compares
the measured sound to decide, whether the part is good or bad. In the past, solutions
came up which did not cope with the complexity of this task:
a) The product material is in general a mixture of different raw materials. Rheological
additives and a heating process influence the stiffness of the part. Inoculation
during the cast process influences the graphite structure.
b) Inhomogeneity of the microstructure or density variation causes an acoustical
variation.
c) Dimensional variation changes the vibration modes of the part.
d) Part temperature affects the elastic modulus and density and thus the resonance
page 1 of 7
(1)
The wave propagation in solids consists of longitudinal and transversal waves with the
sound velocity
cL =
E (1 )
(1 2 )
cT =
E
2 (1 + )
(2)
with E elastic modulus, density and Poissons ratio. Elastic modulus and density are
both temperature dependent.
Any part has an infinite number of resonances, each determined by a specific
combination of material properties and dimensions. Sound testing makes use of this
effect: After suitable stimulation, e.g. by striking, the body vibrates in well-defined
characteristic patterns and frequencies. A sound is a mixture of many single
frequencies (in this case resonances) at a certain level and is not limited to the audible
range but also includes the ultrasonic area. The oscillations, registered with a
microphone, a laser vibrometer or an accelerometer, are so to speak the "language" of
the test object, its distinctive fingerprint. They provide information about the entire test
object and not just locally at the site of the sensor.
Acoustic resonance testing (ART) [2] is a volume-related, non-destructive testing
procedure, which makes the quick and cost-saving 100 % testing of test objects
possible (Fig. 1). Sound testing in line production is an approved technology.
The principal difference between ART and the classic NDT methods is that ART is
sensitive for strength change: a structural defect reduces the stiffness and lowers the
resonant frequency.
Different defect types can be evaluated with one measurement, e. g. cracks, material
deviations and structural deviations (inhomogeneity, stiffness / hardness, porosity). The
main objective is that the defect influences the acoustical behaviour of the part and is
significant with relation to the production scatter.
page 2 of 7
The sensitivity (defect size, defect location) is also related to the part size and shape.
Experimental and theoretical evaluations show that the size of a defect as well as the
defect location has an impact on the frequency values [3]: A larger defect results in the
shift to lower peak frequencies (same defect location) and a deeper defect in the shift to
higher peak frequencies (same defect size). The first influence is higher than the latter
and means that the resonance method is more sensitive for the expansion of a defect
than its location.
The decision for the applicability of the acoustic method requires systematic
engineering and tests prior to automation.
Why compensation?
Various influences the radiation and measurement of the sound and hence the
resonance frequencies (Table 1). In general there are influences from the
manufacturing process (called process-related influences) and influences that come
from the test bench and / or the test system set-up and measurement conditions (called
test-related influences). Especially the excitation to generate the resonance frequencies
is important: Position and direction are responsible for the level of a resonance
frequency. The strength of the excitation can cause a linear or non-linear response
from the specimen resulting in frequency changes and additional frequencies in the
spectrum. The contact time is responsible for the frequency range and the damping of
frequencies.
Influence
Effect
Compen
sation
Method
yes
no
no
no
yes
yes
no
yes
yes
yes
calculation
test objective
test objective
test objective
characteristics
test objective
test objective
characteristics
measurement
measurable
no
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
training strategies
engineering, layout
engineering, layout
engineering, layout
engineering, layout
engineering, layout
engineering, layout
engineering, layout
engineering, layout
engineering, layout
engineering, layout
engineering
engineering, layout
engineering
Process-related influence
Aging
Blowholes
Crack size / location
Density
Dimension
Hardness
Porosity
Raw material
Temperature
Weight
Test-related influence
Human classification
Excitation direction
Excitation force
Excitation position
Excit. contact time
Sensor charact.
Sensor direction
Sensor position
Sensor type
Support material
Support position
Test characteristics
Test environment
Test parameters
Taking all this into account the challenge is to evaluate the impact of these process and
test influences according to a specific test object and test objectives.
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Compensation techniques
As explained above the (accepted) process variation results in the change of specimen
behaviour and thus variation of the resonance frequencies To make the test parts
comparable it is necessary to eliminate this influence as best as possible by adapting
the resonance sprectrum. Within this contribution we explain first some of the process
and then some test related influences.
Precondition of applying frequency compensation is an extremely accurate
measurement. Fig. 2 shows the relative standard deviation related to the vibration
mode of a part with the first vibration mode at 8,5 kHz and the tenth at 78,3 kHz. ART
has an excellent measurement precision of about 0.0035 % at the low frequency and
0.0006 % at higher frequencies [4] and depends only on the frequency resolution
independent of the specific equipment.
Experimental standard deviation (rel.)
0,0000400
Rel. deviation
0,0000350
0,0000300
0,0000250
0,0000200
0,0000150
0,0000100
0,0000050
0,0000000
1
10
Process-related influence
Temperature
Temperature measurement precision depends on a number of factors but can be done
with a precision of 0,5 C. When the temperature of the work piece changes, all
resonance frequencies are affected. A part at lower temperature has a higher stiffness
than a part at higher temperature. The result is a negative shift of the resonances. The
temperature has a linear influence, but the gradient of the straight-line depends on the
frequency (Fig. 3). Fig. 4 shows the effect of temperature compensation.
page 4 of 7
Dimension
To analyse the impact of dimensional variation it is very helpful to know the different
vibration modes on basis of a FEM analysis [5]. Through model variation the
(theoretical) frequency shift can be calculated. The importance of a dimensional
variation depends on the shape of the part and the location of variation, but in general
the influence is, e. g. for a bar:
1. The dimensional variation is proportional to the frequency variation, but with
opposite sign (shift to lower frequencies when the dimension increases).
2. The variation in radial direction (diameter, transversal wave) has much bigger
impact than in axial direction (length, longitudinal wave). A diameter variation
directly affects the stiffness of the part!
3. The impact of a length variation dwindles with increasing resonance frequencies.
4. The impact of a diameter variation increases with increasing resonance
frequencies.
11800
Influence on heigth
frequency [Hz]
11760
11720
11680
11640
11600
11560
11,850
11,900
11,950
12,000
12,050
12,100
12,150
heigth [m m ]
Fig. 5 shows the influence of a dimensional variation, in this case of a toothed ring with
a diameter of 290 mm. The allowed variation of the height of 0,1 mm (0,8 %) causes a
frequency variation of 80 Hz (0,67 %).
Raw material
Concerning acoustic analysis the material properties can simply be characterized by
elastic the modulus E (Youngs modulus), the density , Poissons ratio , bulk /
Copyright 2009 - RTE Akustik+Prftechnik GmbH, Germany
page 5 of 7
(3) [6]
A change of raw material can especially happen on a batch change. This influences the
acoustic resonance response as follows:
1. A positive change for E leads to a positive deviation of resonance frequencies,
weighted by .
2. A positive change for leads to a negative deviation of resonance frequencies,
weighted by . is reciprocal to E (for similar material).
3. The impact by E and is not affected by the value of the resonance frequencies.
4. has no influence in the lower frequency range, but increasing influence in
increasing frequency.
There are different approaches for compensation possible:
a) Use of relative rather than absolute resonance frequencies
b) Include parts with minimum and maximum characteristics
c) Track abnormal / rapid resonance changes and adapt limits
d) Pattern recognition (when rapid changes occur due to natural material variation
Test-related influence
As visible in Table 1 there are many influences caused by the testing conditions. The
compensation of the different items can be achieved, but experience and engineering is
necessary. It is essential for acoustic material testing that the resonance frequencies are
induced to be able to measure them. This is not only a matter of the excitation, but also of
other parameters and system set-up.
Work piece support
Fig. 6 shows the influence of the support material and the number of support contact
positions (within one circle are measurements with a 3-position support and a 4position support; the latter has a bigger damping influence and results in a lower
amplitude!).
Fig. 6: Work piece support influence (left: 3,2 kHz, right: 13 kHz)
Sensor characteristics
Fig. 7 shows the influence of different sensor characteristics (in this case microphones
from different manufacturers). Reasons for this are different sound field sensitivity and
directional characteristics. If you do not use the appropriate sensor you might loose
important information.
Copyright 2009 - RTE Akustik+Prftechnik GmbH, Germany
page 6 of 7
Sensor type
In addition it is a big difference if you use a microphone as a sensor with its integral
capabilities or you use a laser vibrometer or piezoelectric transducer, which measure
the part vibrations at a single position.
Conclusion
Acoustic methods can be applied to the quality control of various kinds of parts.
Sometimes is this the only method to meet the requirements for a fast and
comprehensive evaluation. Product-specific engineering plays a central role for the setup of characteristics and test procedures and creates the basis for the compensation of
process-related influences. The benefit is an objective quality assessment and steadygoing inline high volume production control of high reliability and sensitivity. Guidelines
are necessary and will be provided shortly to describe the approach for successful
applications under the constraint of process and product related variation [8].
References:
[1] Kinsler et. al.: Fundamentals in Acoustics. John Wiley & Sons 2000
[2] Hertlin, I.: Acoustic Resonance Analysis. Informative booklets for non-destructive testing;
Vol. 5; Castell-Verlag, Wuppertal 2003
[3] Asano et. al: Impact acoustics methods for defect evaluation in concrete. International
symposium on Non-destructive testing in civil engineering 2003
[4] Walte et. al.: Einflsse von Bauteiltoleranzen und Bauteilfehlern bei der akustischen
Resonanzanalyse. Jahrestagung DGZfP, Mnster 2009
[5] Hertlin, I.: Acoustic Resonance Analysis Using FEM and Laser Scanning For Defect
Characterization in In-Process NDT. Proceedings of the European Conference on NDT,
Berlin 2006
[6] Heckl, M., Mller, H. A. et. al.: Taschenbuch der Technischen Akustik, Springer-Verlag,
Berlin 1994
[7] Hertlin, I., Rieth-Hoerst, S.: Now Available: Fully Automatic In-line Roofing Tile Inspection.
Tile & Brick International Manual 2007, Verlag DVS
[8] DGZfP - Richtlinie Zerstrungsfreie Prfung mittels akustischer Resonanzverfahren
Methodik, Einflussgren, Voruntersuchungen, Validierung. DGZfP Berlin, 2009 (will be
published)
Copyright 2009 - RTE Akustik+Prftechnik GmbH, Germany
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