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Simulation and experimental results of manual UT-testing of hollow wheel set axles during the education of operators

  • The reliability of wheel set axle testing is of high importance because small discontinuities caused during manufacturing or rock fall impacts during operation might cause growing cracks during the operation load cycles. While most of the axles are tested by automated UT-systems today, the basic education of railway NDT operators is still manual testing providing the basic understanding and skills for the operators. In Germany it is a common rule that NDT operators in the railway branch need to refresh their knowledge and skills every five years including a refresh examination. The testing results from these exercises and from a parallel round robin test have been sampled at the DGZfP Railway Education Centre in Wittenberge for a period of about 5 years. The results of the operators written in test record sheets were compared with the “true” test crack or notch position in the axles used for examination. In this way the testing results could be categorized into “hits” and “misses” andThe reliability of wheel set axle testing is of high importance because small discontinuities caused during manufacturing or rock fall impacts during operation might cause growing cracks during the operation load cycles. While most of the axles are tested by automated UT-systems today, the basic education of railway NDT operators is still manual testing providing the basic understanding and skills for the operators. In Germany it is a common rule that NDT operators in the railway branch need to refresh their knowledge and skills every five years including a refresh examination. The testing results from these exercises and from a parallel round robin test have been sampled at the DGZfP Railway Education Centre in Wittenberge for a period of about 5 years. The results of the operators written in test record sheets were compared with the “true” test crack or notch position in the axles used for examination. In this way the testing results could be categorized into “hits” and “misses” and the “hits” were further evaluated due to correct position and adequate amplitude height. Considering some thousand indications documented by the operators during the refresh examination and comparing transition bow, shaft and seat it was a highlight to see that the operators reach their best detection rate in the transition bow of the wheel axle set while this is often the most difficult part concerning the UT-echoes. Fortunately this is due to their raised awareness in the transition bow region because this is the most dangerous region with respect to fracture mechanics. For two selected axles the experimental set up of 45° and 70° inward and outward UT-testing were also simulated showing clearly the difficulties of the UT-echoes detection of some specific test defects.zeige mehrzeige weniger

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Metadaten
Autor*innen:Gerd-Rüdiger Jaenisch
Koautor*innen:Christina Müller, Mato Pavlovich, Ludwig Bartsch, Martina Rosenthal, R. Holstein
Dokumenttyp:Vortrag
Veröffentlichungsform:Präsentation
Sprache:Englisch
Jahr der Erstveröffentlichung:2016
DDC-Klassifikation:Naturwissenschaften und Mathematik / Chemie / Analytische Chemie
Freie Schlagwörter:Education of NDT personnel; Fault tree analysis; Manual testing; NDT reliability; Ultrasound
Veranstaltung:XXII Saint-Petersburg Conference on Ultrasonic Testing of Metals and Advanced Materials (UTM 2016)
Veranstaltungsort:St. Petersburg, Russia
Beginndatum der Veranstaltung:24.05.2016
Enddatum der Veranstaltung:27.05.2016
Verfügbarkeit des Dokuments:Datei im Netzwerk der BAM verfügbar ("Closed Access")
Datum der Freischaltung:01.08.2016
Referierte Publikation:Nein
Eingeladener Vortrag:Nein
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