Ver3 Date: Jan $1 2008 aio (New jig version) This Operation Manual define the way of the ultrasonic inspection operating for the KYB friction welding red by the specific ultrasonic detector ” Krauthramer USM 35X ” 2. Equipments and Testing Way ‘ 1) Detector: Model : USM 35%. Make: Krautkramer 2) Probe: Angle prove SZ10X10A45 2) Calibration blocks sTB-A3 4) Couptent 78% alycerin liquid or Hydraulic of 5) Scanning Method ‘Angle double prove technique 3, Calibration (Fully Time seale 150mm) Use the suto-calibration mode of the detector "USN-25X” Calibration should be done every week Duleke sure the detector plane of the probes does not have eny angie by eyes. Dlurn on the detector. ‘DOonnect the angle probe (5Z10K10A45) cable to the transmitting terminal (T) on the detector. ‘@Push the mode select key until the calibration mode “CAL"is displayed. Set the standard reference path length 1 "S-REFI” 50mm. ‘Set the ctandard reference path length 2."S-REF2” 100mm. [Set “S-REFI™ Node Select Key | ftode cisplay [Set the mede “CAL” Make sure the threshold of a~Gate “aGAT™ is 50%, i not, set it 508 according to LISM-35X instruction manual, @PSelect “a Start” with pushing the furction key. (“a Start” means start point of the a-Gate) [Make sure the theshold of a~ Gate “2GAT” is Select “a Start” with sushing the function key. "a Start” means stert point of the a-Gate.)leain dial. [Set the Frat esho level {80% with changing the aro) @Put the couplant on the calibration bleck,"STB-Ad", and out the probe on the slit which positions on the center of the R50, ‘Then, position the orcbe detecting direction toward the end point of the R50, Put the probe on the allt which positions on the Jeantor of the REC. @® Set the first echo level 80% with changing the gain cial @© Change the “a START” to cross the frst echo to threshold of a~Gate. @ Push the enter key to memorize the Echo position, [Charge the “a START" to cross Posi) land confirm echo position is memorized. lthe first echo to leheshold of o— D Set the second echo level 80% with changing the gain dial @ Change the “a START” to cross the second echo to threshold of a~Gate, D Push the enter key to finish the time range setting. @® The display will show that Calibration is finished. iat finished [Set the second lecho level 80% with Ichanging the gain The display will show that Calbration is (Change tha “a START” to crass Ithe second echo to ‘theshold of@Make sure the echo periods are the senie interval ‘@/10) [Make cure te lecho periods are ‘the same interval. caro) 4. Reference sensitivity level setting (DPut the reference cencitivity level eatting jis on the actual work. Note: +Solect the correct jig by rod size. “Attached shest 1 shows the detail dimensions of the jie. ®insert the probes into the hele of the ji the the fet Note “Put the eauplant on the probe surface before inserting it. (5/10) @ Set the Acceptance sensitivity level of the UT detector 24s more than reference sensitivity level Example: In oase that Reference sensitivity level settings 203B, Acceptance level willbe 20 + 24 = 448) QSet the jig on the rod. Note: *Solact the ecrract jig by rod siz “Attached cheet 2 chows the detail dimencions of the jig @Put the Couplant on the checking part then put the vig on the work. Note: “Put the probe hole side of the jig toward the rod eye side. *Position the end of the jig to tha welding bead cutting end. Attached sheet 3, jig setting position sheet, shows distance A which is the distance ‘rom welding boundary to the welding bead cutting end, Sn @ Insert the probes into the hole of the jie Note: Put the couplant on the surface of the probes. “Transmission direction of the probes must be set toward the rod eve side.10) GP ress the probe in the fixed hole side against the rod slightly. The sliding hole side probe should be Smm back from the front of the slot on the jig. Then slide the siding hole side probe -t5mm with pressing slightly against the rod to find the maximum echo height position. Desital display shows the height lof the echo peak. @Aiter find the maximum acho height position, keep the position of the sliding hole side, Rotate the jig more than 180° with keeping the position of the probes by hand. Make sure couplant sticks between the rod and the probes. During the rotation, check the echo height. Qdudgment If echo heisht during the testing is less than 50%, it is acceptable. If echo height is 50% or more, the work is NG. If echo height during the testing is less than 50%, it is acceptable.a) @®About reflecting position _ = Fig 1 ‘The path length of the echo reflected form friction welding boundary ie conetant based on the formula 1, even if the position of the probes is changed ‘The probes should be located around D/2 away from the welding boundary. (Fig 1) thas some possiblity the probe catches the echo ‘rom rod eye hole if the proves are located too close or too far from D/2 away from the welding boundary (Fig.2) Ifthe echo path length is cut of the table -+ 10mm, the echo should be the following echo. “Scattered echo Reflected echo from the rad eye hole, Formula 1. Echo path length = Rod Diametor x 1/2 1.414 Following chart shows the Echo path length by Rod Diameter. Outside Demeter Echo lof Piston Rod path length O85 60.1 mm 90 63.6 mm O95 67.2 mm 100 70.7 mm $105 74.2 iAttached Sheet 1 Reference leve setting Vig Drawing Now J ero (For Probe Node SZ10x10MB MAKERVAPAN PROBE) [rz ae e = ee) “aban ed eet a & = srr Getinta] “aba (eat dl ean Aw [ 1 1 | oore [_ A Ee TT ae | a BC 9 | eta weer a i i Was te pelea ew pat | | Sofas has sexe | ! | 10 Wo i li a 02 1Sa7 S980 CER BREE IS 1 sai | QRABARYAMISE) Ib (REMERTE) IT UBB /MIAHRS 237M LAWS “LES FA + oa RO f__ ae TR aa To 125 fame ues : a « o|_ Baru ERR je CHECKED ex arAT TeeawerT _ EE a} le aT] S000 | ar esr — res rae a % Re] FvEpR 08002 Bes KAYABA INDUSTRY CO,LTD, WWE AP NISERSE‘Avached sheet 2 UT Irspecton Jig Drawing (For Probe Model §210x(0A45 MAKERWAPAN PROBE) Kew Jig (90) oa =e ra ma TEES oF] & BT a is ae | Eee 3] #8 [Ras | ters [a | 8s | as Larenf((] || REerte hee | | care i 155 FMRC IE BBR 3 jeer] | | at DANY AMLSK/ Tb CRENESTA) t 1 SRB /NTASRIS p2ONT IIE abel TAPS EWE TRE ES EAE EF ons fw ete sar a 5 % Lt ieria A REREUTRE ASR jae caecKED fie SWEAT TaEaTRERT at aa : jeu [SE Tag free ren Be] FNEPR-O6001 (eel sooo [= KAYABA INDUSTRY GO,LTD, HWie AVN ITRGRALAttached Sheet 3 UT Inspection Jig setting Position Welding bead cutting end UT Inspection Jig setting Position sheet 10/10) A=Distance from welding boundary to welding bead cutting end and jig end. 13.0 mm 13.0 mm 14.0 mm 14.0 mm 15.0 mm