Microcrack Detection Using Spectral Response Data Alone

Microcracks of depth less than 200 μm in mechanical components are difficult to detect because conventional methods such as X-ray or eddy current measurements are less sensitive to such depths. Nonetheless, an efficient microcrack detection method is required urgently in the mechanical industry because microcracks are produced frequently during cold-forming. The frequency response function (FRF) is known to be highly sensitive even to microcracks, and it can be obtained using both the input data of an impact hammer and the response data of an accelerometer. Under the assumption of an impulse force with a similar spectral impulse pattern, spectral response data alone could be used as a crack indicator because the dynamic characteristics of a microcrack may be dependent solely on these measured data. This study investigates the feasibility of microcrack detection using the response data alone through impact tests with a simple rectangular specimen. A simple rectangular specimen with a 200 μm microcrack at one face was prepared. The experimental modal analysis was conducted for the normal (uncracked) specimen and found-first bending mode about 1090 Hz at the X-Y plane (in-plane). Response accelerations were obtained in both at in-plane locations as well as X-Z plane (out-of-plane), and the crack was detected using the coherence function between a normal and a cracked specimen. A comparison of the crack inspection results obtained using the response data and the FRF data indicated the validity of the proposed method.