Abstract
Spherical pressure vessels as fuel storage for space uses are usually made by the spinning process and precise control of thickness is a prerequisite. The non-contact thickness measurement method is necessary in such a case. Laser ultrasonic technique (LUT) is highly appreciated in this case of non-contact measurement. As a significant amount of surface roughness, i.e., roller wake produced during radial and axial feeding of the roller to the cylinder, the objective of this study is to investigate the effect of rough surfaces generated by the spinning process on thickness measurement using laser-generated ultrasound through experiment. This paper describes the variations in average thickness and amplitude of thickness measured by contact gauge and LUT at hill and valley portion of the roller wake of spinning processed cylinder. Some underestimation occurs at the hill case. The maximum amount of underestimation was about 0.04 mm. The variation in thickness caused by the spinning process can also be measured with no contact by the proposed LUT method. The maximum relative change in thickness due to the spinning process was about 9.5%. Necessary adjustment based on the finding can be a key to establish an efficient real-time thickness measurement system in the spinning process for economic and reliable production of a spherical pressure vessel.
Similar content being viewed by others
References
Akkus N, Kawahara M (2006) An experimental and analytical study on dome forming of seamless Al tube by spinning process. J Mater Process Technol 173(2):145–150. https://doi.org/10.1016/j.jmatprotec.2005.11.011
Kalpakjian S, Rajagopal S (1982) Spinning of tubes: a review. J Appl Metalwork 2(3):211–223. https://doi.org/10.1007/BF02834039
Roy MJ, Maijer DM (2015) Analysis and modelling of a rotary forming process for cast aluminium alloy A356. J Mater Process Technol 226:188–204. https://doi.org/10.1016/j.jmatprotec.2015.06.036
Jianguo Y, Makoto M (2005) An experimental study on spinning of taper shape on tube end. J Mater Process Technol 166(3):405–410. https://doi.org/10.1016/j.jmatprotec.2004.08.025
Huang CC, Hung JC, Hung C, Lin CR (2011) Finite element analysis on neck-spinning process of tube at elevated temperature. Int J Adv Manuf Technol 56:1039–1048. https://doi.org/10.1007/s00170-011-3247-0
Levin VA, Perezhogin VN, Khmelevskii AN (1995) Features of combustion product flow structure in a spherical semi-open cavity. Combust Explos Shock Waves 31(1):30–36. https://doi.org/10.1007/BF00755952
Fazeli AR, Ghoreishi M (2011) Statistical analysis of dimensional changes in thermomechanical tube-spinning process. Int J Adv Manuf Technol 52:597–607. https://doi.org/10.1007/s00170-010-2780-6
Nahrekhalaji ARF, Ghoreishi M, Tashnizi ES (2010) Modeling and investigation of the wall thickness changes and process time in thermo-mechanical tube spinning process using design of experiments. Engineering 02:141–148. https://doi.org/10.4236/eng.2010.23020
Lee HS, Yoon JH, Park JS, Yi YM (2005) A study on failure characteristic of spherical pressure vessel. J Mater Process Technol 164–165:882–888. https://doi.org/10.1016/j.jmatprotec.2005.02.208
Jiang SY, Zheng YF, Ren ZY, Li CF (2009) Multi-pass spinning of thin-walled tubular part with longitudinal inner ribs. Trans Nonferrous Met Soc China 19:215–221. https://doi.org/10.1016/S1003-6326(08)60255-1
Liu CH (2007) The simulation of the multi-pass and die-less spinning process. J Mater Process Technol 192–193:518–524. https://doi.org/10.1016/j.jmatprotec.2007.04.021
Wang L, Long H (2011) Investigation of material deformation in multi-pass conventional metal spinning. Mater Des 32:2891–2899. https://doi.org/10.1016/j.matdes.2010.12.021
Ram Mohan T, Mishra R (1972) Studies on power spinning of tubes. Int J Prod Res 10(4):351–364. https://doi.org/10.1080/00207547208929937
Zoghi H, Arezoodar AF (2013) Finite element study of stress and strain state during hot tube necking process. Proc Inst Mech Eng Part B J Eng Manuf 227(4):551–564. https://doi.org/10.1177/0954405413476495
Roy MJ, Klassen RJ, Wood JT (2009) Evolution of plastic strain during a flow forming process. J Mater Process Technol 209:1018–1025. https://doi.org/10.1016/j.jmatprotec.2008.03.030
Roy BK, Korkolis YP, Arai Y, Araki W, Iijima T, Kouyama J (2018) Experiments and simulation of shape and thickness evolution in multi-pass tube spinning. J Phy Conf Series 1063(1):012087. https://doi.org/10.1088/1742-6596/1063/1/012087
Šugár P, Šugárová J, Petrovič J (2016) Analysis of the effect of process parameters on part wall thickness variation in conventional metal spinning of Cr-Mn austenitic stainless steels. Strojniski Vestnik/J Mech Eng 62(3):171–178. https://doi.org/10.5545/sv-jme.2015.2901
Xiao G, Li Y, Xia Q, Cheng X, Chen W (2019) Research on the on-line dimensional accuracy measurement method of conical spun workpieces based on machine vision technology. Measurement: J Int Measurement Confederation 148:106881. https://doi.org/10.1016/j.measurement.2019.106881
Monchalin JP, Neron C, Bussiere JF et al (1998) Laser-ultrasonics: from the laboratory to the shop floor. Adv Perform Mater 5:7–23. https://doi.org/10.1023/a:1008644903553
Liu P, Nazirah AW, Sohn H (2016) Numerical simulation of damage detection using laser-generated ultrasound. Ultrasonics 69:248–258. https://doi.org/10.1016/j.ultras.2016.03.013
Sangkharat T, Dechjarern S (2022) On-line thickness measurement system for the metal spinning process. Int J Technol 13(1):202–212. https://doi.org/10.14716/ijtech.v13i1.5025
Jeskey G, Kolarik R, Damm E et al (2004) Laser ultrasonic sensor for on-line seamless steel tubing process control. In: Proc 16th World Conf Nondes Test, Montreal (Canada), pp 469–477. https://www.ndt.net/article/wcndt2004/pdf/in-process_ndt-nde/469_jeskey.pdf
Lévesque D, Kruger SE, Lamouche G et al (2006) Thickness and grain size monitoring in seamless tube-making process using laser ultrasonics. NDT E Int 39:622–626. https://doi.org/10.1016/j.ndteint.2006.04.009
Burrows SE, Fan Y, Dixon S (2014) High temperature thickness measurements of stainless steel and low carbon steel using electromagnetic acoustic transducers. NDT E Int 68:73–77. https://doi.org/10.1016/j.ndteint.2014.07.009
Jafarabadi MA, Mahdieh MH (2015) Investigation of phase explosion in aluminum induced by nanosecond double pulse technique. Appl Surf Sci 346:263–269. https://doi.org/10.1016/j.apsusc.2015.03.158
Watson S, Field JE (2000) Measurement of the ablated thickness of films in the launch of laser-driven flyer plates. J Phys D Appl Phys 33:170–174. https://doi.org/10.1088/0022-3727/33/2/312
Guo H, Zheng B, Liu H (2017) Numerical simulation and experimental research on interaction of micro-defects and laser ultrasonic signal. Opt Laser Technol 96:58–64. https://doi.org/10.1016/j.optlastec.2017.04.004
Liu Y, Yang S, Gan C (2015) A novel laser ultrasonic thickness measurement method for metal plate based on spectral analysis. In: 12th Int Conf Ubiquitous Robot Ambient Intell (Urai), pp 324–329. https://doi.org/10.1109/URAI.2015.7358964
Rahman MM, Elsayed-Ali HE (2021) On-line thin film thickness monitor by pulsed laser photoacoustics. Opt Lasers Eng 139:106482. https://doi.org/10.1016/j.optlaseng.2020.106482
Davis G, Nagarajah R, Palanisamy S et al (2019) Laser ultrasonic inspection of additive manufactured components. Int J Adv Manuf Technol 102:2571–2579. https://doi.org/10.1007/s00170-018-3046-y
Rus J, Grosse CU (2021) Thickness measurement via local ultrasonic resonance spectroscopy. Ultrasonics 109:106261. https://doi.org/10.1016/j.ultras.2020.106261
Cavuto A, Martarelli M, Pandarese G et al (2015) Experimental investigation by laser ultrasonics for high speed train axle diagnostics. Ultrasonics 55:48–57. https://doi.org/10.1016/j.ultras.2014.08.010
Moreau A, Lévesque D, Lord M et al (2002) On-line measurement of texture, thickness and plastic strain ratio using laser-ultrasound resonance spectroscopy. Ultrasonics 40:1047–1056. https://doi.org/10.1016/S0041-624X(02)00255-X
Nakano H, Matsuda Y, Shin S, Nagai S (1995) Optical detection of ultrasound on rough surfaces by a phase-conjugate method. Ultrasonics 33(4):261–264. https://doi.org/10.1016/0041-624X(95)00039-6
Scruby CB (1989) Some applications of laser ultrasound. Ultrasonics 27:195–209. https://doi.org/10.1016/0041-624X(89)90043-7
Moss BC, Scruby CB (1988) Investigation of ultrasonic transducers using optical techniques. Ultrasonics 26(4):179–188. https://doi.org/10.1016/0041-624X(88)90065-0
Cong S, Gang T (2012) Ultrasonic thickness measurement for aluminum alloy irregular surface parts based on spectral analysis. Trans Nonferrous Met Soc China 22(SUPPL.2):s323–s328. https://doi.org/10.1016/S1003-6326(12)61726-9
Nagy PB, Adler L (1987) Surface roughness induced attenuation of reflected and transmitted ultrasonic waves. J Acoust Soc Am 82(1):193–197. https://doi.org/10.1121/1.395545
Meireles JB, Da Silva L, Caetano DP, Huguenin JAO (2012) Effect of metallic surface roughness on the speckle pattern formation at diffraction plane. Opt Lasers Eng 50(12):1731–1734. https://doi.org/10.1016/j.optlaseng.2012.07.009
Wong PL, Li KY (1999) In-process roughness measurement on moving surfaces. Opt Laser Technol 31(8):543–548. https://doi.org/10.1016/S0030-3992(99)00108-5
Peiponen KE, Tsuboi T (1990) Metal surface roughness and optical reflectance. Opt Laser Technol 22(2):127–130. https://doi.org/10.1016/0030-3992(90)90022-V
Fuse N, Kaneshige K, Watanabe H (2014) Development of thickness measurement system for hot steel with laser-ultrasonic wave technology. Mater Trans 55(7):1011–1016. https://doi.org/10.2320/matertrans.I-M2014811
Roy BK, Korkolis YP, Arai Y, Araki W, Iijima T, Kouyama J (2021) Influence of axial feed rate on shape and thickness changes during multi-pass tube spinning: experiments and modelling. In :Forming the Future: Proc of the 13th Int Conf on the Technol of Plasticity, Springer Int Pub, pp 2127–2134. https://doi.org/10.1007/978-3-030-75381-8_179
Roy BK, Korkolis YP, Arai Y, Araki W, Iijima T, Kouyama J (2021) A study of forming of thin-walled hemispheres by mandrel-free spinning of commercially pure aluminum tubes. J Manuf Process 64(February):306–322. https://doi.org/10.1016/j.jmapro.2020.12.036
Roy BK, Korkolis YP, Arai Y, Araki W, Iijima T, Kouyama J (2020) Experimental and numerical investigation of deformation characteristics during tube spinning. Int J of Adv Manuf Technol 110(7–8):1851–1867. https://doi.org/10.1007/s00170-020-05864-z
Cavuto A, Sopranzetti F, Martarelli M, Revel GM (2013) Laser-ultrasonics wave generation and propagation FE model in metallic materials. J Clin Exp Dent 7:628–633. https://www.comsol.fr/paper/download/181573/cavuto_paper.pdf
Kim N, Hong M (2009) Measurement of axial stress using mode-converted ultrasound. NDT E Int 42(3):164–169. https://doi.org/10.1016/j.ndteint.2008.09.005
Acknowledgements
The financial assistance provided by the Ministry of Education, Culture, Sports, Science, and Technology of Japanese Government is gratefully acknowledged. This study is supported by the Strength of Material Laboratory of Saitama University and Asahi Seisakusho Co. Ltd., Japan. Also, I would like to acknowledge the study support provided by Department of Mechanical Engineering, Rajshahi University of Engineering and Technology, Bangladesh.
Funding
The Japanese Ministry of Education, Culture, Sports, Science and Technology (Monbu-kagaku-shō, or MEXT) Scholarship.
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Competing interests
The authors declare no competing interests.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Rahim, M., Arai, Y. & Araki, W. Effects of thickness variation due to presence of roller wake on the thickness measurement using laser ultrasonic technique. Int J Adv Manuf Technol 132, 339–348 (2024). https://doi.org/10.1007/s00170-024-13397-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-024-13397-y