Integration of confocal chromatic spectroscopy into a test bench concept for safety inspection practices, with focus on stress detection

Abstract

Abstract Evaluating casting’s mechanical stress is of significant interest from a safety inspection’s point of view. Residual stress, in particular, leads to an early or even immediate failure of some parts. Therefore, several methods exist to determine casting’s external and internal strain leading to stress. By determining the state of stress and residual stress, it is possible to design casting parts that are much safer. The present concept of a test bench shows a new way of inspecting parts for safety reasons using an optical fiber confocal chromatic sensor to measure strain. The method is based on the deep-drilling method, where a minimal invasive hole is placed at an area of interest in the first step. In a second step, this hole is then precisely measured to be able to map the borehole. From this information, conclusions can be drawn of any forces acting on the inspected part. In this case, the concept of the test bench uses gun drills to place boreholes measuring 6.0 mm in diameter with up to 500.0 mm in depth, and for the inspection, a confocal sensor with a precision of ± 100.0 nm in dissolving distances is used. This work focuses on evaluating the test bench’s precision in conducting such measurements and on how an external thermal load and mechanical load influence the results when conducting differential measurements. The experiments are performed on typical cast alloys such as iron cast and Zamac.

Keywords

• Gun drilling
• Confocal spectroscopy
• Castings
• Safety and stress inspection