Estimation of stress distribution in ferromagnetic tensile specimens using low cost eddy current stress measurement system and BP neural network

Estimation of the stress distribution in ferromagnetic components is very important for evaluating the working status of mechanical equipment and implementing preventive maintenance. Eddy current testing technology is a promising method in this field because of its advantages of safety, no need of coupling agent, etc. In order to reduce the cost of eddy current stress measurement system, and obtain the stress distribution in ferromagnetic materials without scanning, a low cost eddy current stress measurement system based on Archimedes spiral planar coil was established, and a method based on BP neural network to obtain the stress distribution using the stress of several discrete test points was proposed. To verify the performance of the developed test system and the validity of the proposed method, experiment was implemented using structural steel (Q235) specimens. Standard curves of sensors at each test point were achieved, the calibrated data were used to establish the BP neural network model for approximating the stress variation on the specimen surface, and the stress distribution curve of the specimen was obtained by interpolating with the established model. The results show that there is a good linear relationship between the change of signal modulus and the stress in most elastic range of the specimen, and the established system can detect the change in stress with a theoretical average sensitivity of -0.4228 mV/MPa. The obtained stress distribution curve is well consonant with the theoretical analysis result. At last, possible causes and improving methods of problems appeared in the results were discussed. This research has important significance for reducing the cost of eddy current stress measurement system, and advancing the engineering application of eddy current stress testing.