Memory-Efficient Approach to Modeling Piezoelectric Immersion Ultrasonic Testing of Tubes

Abstract

During ultrasonic internal inspection experiments, environmental fluctuations and operational errors inevitably introduce deviations in the results, while the obtainable parametric data remain limited. Therefore, it is necessary to conduct ultrasonic internal inspection simulations and establish a digital R and D platform for ultrasonic inspection devices to enhance the accuracy and generalizability of the results. However, simulating ultrasonic internal inspection is an extremely complex process. At a detection frequency of 5 MHz, solving the constructed 3D model demands substantial computational resources, including memory exceeding 1 TB and extended runtime. To address this challenge, a simulation model for ultrasonic internal inspection of volumetric defects with circumferential symmetry in wave propagation was developed using COMSOL software, based on process parameters from an actual piezoelectric ultrasonic inspection experimental platform. The actual inspection process was divided into three stages: ultrasonic emission, propagation and reception. Corresponding 3D, 2D and 3D simulation models were established, along with parameter transfer methods between each stage. The model’s accuracy was verified by comparing simulation and experimental results in four aspects: waveform similarity, amplitude variation rate, dominant peak frequency and wall thickness. By turning the whole into parts, the simulation model for a single inspection consists of 26 combined simulations, each with significantly reduced memory requirements—enabling execution on standard computers. The established model effectively and clearly describes the entire internal inspection process.