CN109014518B - Welding device and repairing process for train wheel die holder - Google Patents
Welding device and repairing process for train wheel die holder Download PDFInfo
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- CN109014518B CN109014518B CN201811080981.XA CN201811080981A CN109014518B CN 109014518 B CN109014518 B CN 109014518B CN 201811080981 A CN201811080981 A CN 201811080981A CN 109014518 B CN109014518 B CN 109014518B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/235—Preliminary treatment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
Abstract
The invention discloses a train wheel die holder welding device, which comprises a welding gun, a die holder rotating support, an annular heating device, rotating equipment and a die holder supporting seat; the annular heating device is fixedly arranged above the die holder rotating support through the heater support; the rotary equipment is fixedly arranged at the central position of the top of the die holder rotary support, the top of the rotary equipment is provided with a die holder supporting seat, and the die holder supporting seat is positioned below the central position of the annular heating device; the welding gun is arranged at the position of the annular heating device. The invention also discloses a train wheel die holder repairing process. The invention can rapidly implement and finish the abrasion welding repair of the contact surface of the train wheel die holder, saves rolling time, reduces purchasing cost, reduces long-time shutdown loss, and provides guarantee for reasonably producing steel rolling to produce various domestic and foreign wheels.
Description
Technical Field
The invention belongs to the field of machinery, relates to a die holder welding device and a repairing process, and in particular relates to a train wheel die holder welding device and a repairing process.
Background
The horse steel wheel company is an important train wheel production base in China, is the largest wheel production enterprise in Asia, is also the only enterprise in China capable of producing the bus wheels with the speed grade of more than 120Km/h, and the research and development of heavy-load wheels reach the international advanced level. The method is characterized in that two wheel production lines are shared by the company at present, the annual production capacity is 80 ten thousand, the wheel rolling three-line is built into production in 2008 in 10 months, the wheel rolling three-line is one of the wheel production lines with the shortest flow, the highest automation degree and the strongest specialization in the world, the core process for producing the wheel is that heated red steel is conveyed to the upper surface of a wheel die holder of the next working procedure through a manipulator, then the wheel is rolled by a ten thousand ton oil press, the die holder is used as an important part in the wheel pressing process, the wheel die and a movable cross beam of the wheel press play a role of a transitional connector, the working load of ten thousand tons is born in production, the matching surface between the die and the movable cross beam is damaged after the die holder is used for a period of time due to the huge rolling pressure, as shown in a wearing surface 14 in fig. 4, the rolling quality of the wheel product is affected, if a new die holder is replaced, not only millions of spare parts are needed, but also the period of purchasing and the new spare parts are required to be processed. Therefore, in order to restore production as soon as possible, it is necessary to design a simple device, develop and perfect a wear surface welding and heat treatment process based on different base materials, develop a die holder welding repair relationship, and ensure that the worn die holder can be reused economically, safely and reliably.
At present, various die holder welding repair applications are common, and various documents are described, but the welding repair of a train wheel die holder is rare, and the main difficulty of the welding repair of the train wheel die holder is that after the welding processes of heating, operating, heat preservation and the like of a die holder part to be welded are completed, the integral die holder is ensured not to be structurally deformed, and the precision installation of other rolling assemblies matched with the die holder and various substandard performances of internal tissues are not influenced. In addition, the die holder after surfacing meets the requirement that the mechanical processing reaches the operation size, and the surface cannot have any welding defects so as to avoid the subsequent influence on the quality of the operation period.
Disclosure of Invention
Aiming at the characteristic of abrasion weldability of the contact surface of the train wheel die holder, the invention designs and manufactures a set of abrasion welding device of the contact surface of the train wheel die holder, prepares and restores the technology to be implemented, and can quickly implement and complete the abrasion welding restoration of the contact surface of the train wheel die holder through welding verification, thereby saving rolling time, reducing purchasing cost, reducing long-time shutdown loss and providing guarantee for reasonably producing rolled steel to produce various domestic and foreign wheels.
The technical scheme for solving the technical problems is as follows:
the invention relates to a train wheel die holder welding device which is characterized by comprising a welding gun, a die holder rotating support, an annular heating device, rotating equipment and a die holder supporting seat; the annular heating device is fixedly arranged above the die holder rotating support through the heater support; the rotary equipment is fixedly arranged at the central position of the top of the die holder rotary support, the top of the rotary equipment is provided with a die holder supporting seat, and the die holder supporting seat is positioned below the central position of the annular heating device; the welding gun is arranged at the position of the annular heating device.
As a further improvement of the technical scheme, the top of the heater support is welded and fixed with the bottom of the annular heating device, the lower part of the heater support is connected with the die holder rotating support in an up-down adjustable mode, and a limiting block is arranged on the heater support.
As a further improvement of the technical scheme, the annular heating device comprises a gas pipeline, an annular pipeline and a plurality of burners; the gas pipeline is communicated with the annular pipeline, and the burner is uniformly arranged on the inner side of the annular pipeline.
As a further improvement of the technical scheme, the gas pressure regulating valve is arranged on the gas pipeline.
As a further improvement of the technical scheme, the inner side of the annular pipeline is also provided with an insulating layer.
As a further improvement of the technical scheme, a central ejector rod is arranged at the central position of the die holder supporting seat.
The other technical scheme for solving the technical problems is as follows:
the train wheel die holder repairing process adopting the technical scheme of the train wheel die holder welding device comprises the following steps of:
step one, preparing before welding:
1.1 Preparing welding equipment; the welding equipment is divided into two types, namely a digital pulse gas shielded welder, a direct current positive connection is adopted, a matched welding material is selected as a flux-cored welding wire, and the shielding gas is carbon dioxide with the purity of more than or equal to 99.8%; secondly, digitally controlling the inverter type manual direct current welder, selecting an E5015 electrode as a matched electrode, baking, keeping constant temperature, and taking along with use;
1.2 Determining a region of a die holder to be welded, degreasing, removing moisture and an oxide layer on the region, firstly removing the greasy dirt and the moisture by using oxyacetylene flame, and then polishing and derusting by using a abrasive cloth or a nitrogrinding machine;
1.3 Placing the die holder processed in step 1.2) on a die holder supporting seat, and fixing a welding gun of the digital pulse gas shielded welding machine as a fixing welding gun in a region of a position, where the die holder needs to be welded;
1.4 Determining the technological parameters of die holder welding according to the welding equipment and the matched welding materials determined in the step 1.1);
1.5 Preparing auxiliary facilities required by welding;
step two, preheating and welding;
2.1 Introducing fuel gas into the fuel gas pipeline, and preheating the die holder to 150-200 ℃ from the outer side of the die holder by utilizing each burner of the annular heating device;
2.2 Because the area of the die holder where the welding is needed is an annular fillet weld, starting a rotating device in a gradual upward welding mode, adjusting the running direction and the running speed of the rotating device, enabling the running speed of the die holder placed on the rotating device to be matched with the preset welding speed, then performing bottom layer clockwise welding on the area of the die holder where the welding is needed by a fixed welding gun, enabling the angle of the welding gun to meet the fusion of the bottom and the side face of a die holder wearing surface during welding, adopting an oblique triangle strip method short arc or a medium arc length of 15-22 mm, enabling the width of the welding line to be 8-10 mm, closing the rotating device after the end of the welding line of the bottom layer is connected, cleaning and checking whether welding defects exist on the welding line or not, performing repair welding after back chipping welding is performed by adopting a plasma gouging cutter, performing repair welding by adopting a manual welding rod through digital control inversion manual direct current welder, performing repair welding by adopting E5015 welding rod, maintaining the interlayer temperature during repair welding, and checking the welding line again after repair welding, and ensuring no welding defects;
2.3 Welding two layers and more than two surfacing layers by using rotating equipment again, performing welding of each surfacing layer by using a fixed welding gun in a short arc or 15-22 mm medium arc length by using an inverse moon-shaped strip conveying method, ensuring that each surfacing layer is kept at 8-10 mm width, ensuring that the surfacing layers are well fused with the wear surface of a die holder when fillet weld surfacing is performed, performing weld defect inspection on each surfacing layer after head-tail connection in the welding process, performing back gouging by using a plasma gouging cutter if welding defects such as cracks and air holes exist, performing repair welding by using a manual electrode arc welding by using an E5015 electrode by using a digital control inverse direct current manual welding machine, maintaining interlayer temperature during repair welding, and checking the weld again after repair welding to ensure no welding defects;
2.4 Welding a top cover surface layer, welding by using a rotating device through a fixed welding gun, wherein the width of a welding seam is 15-20 mm, the welding seam needs to cover a build-up welding layer and a die holder body, then performing omnibearing welding inspection, directly observing or looking up the welding seam by using a magnifying glass 3-4 times of magnifying glass to be qualified, and dismantling the fixed welding gun after confirming that no welding defect exists;
step three, post-welding treatment;
3.1 Starting the annular heating device again, continuously heating the integral die holder to 350-450 ℃, wrapping with heat-insulating cotton, covering the die holder, and cooling to room temperature;
3.2 And (3) machining the welded integral die holder through a machine tool to enable the integral die holder to reach the assembly size.
As a further improvement of the technical scheme, the diameter of a flux-cored wire matched with the digital pulse gas shielded welding machine is 1.2mm, the welding current is 260-280A, the arc voltage is 26-28V, the deposition speed is 90g/min, the welding current is 280-320A, the arc voltage is 28-32V, and the deposition speed is 90-140 g/min when the overlay layer and the overlay layer are welded; the diameter of an E5015 electrode selected as a matched electrode of a digital control inversion type manual direct current welder is 3.2mm and 4.0mm, the temperature is kept after baking for 2 hours at 350-400 degrees before use, the temperature is kept along with the use, the E5015 electrode with the diameter of 3.2mm is adopted when the bottom layer is subjected to repair welding, the welding current is 120-180A, the arc voltage is 23+/-1V, the welding speed is 15+/-1 cm/min, the E5015 electrode with the diameter of 4.0mm is adopted when the overlay layer and the cover layer are subjected to repair welding, the welding current is 180-220A, the arc voltage is 26+/-1V, and the welding speed is 17+/-1 cm/min.
As a further improvement of the technical scheme, in the step 2.1), when the die holder is preheated from the outer side of the die holder by using each burner of the annular heating device, the temperature rising speed is 50℃/h; and 3.1) starting the annular heating device again to continuously heat the integral die holder, wherein the temperature rising speed is 150℃/h.
As a further improvement of the technical scheme, the bottom layer, each surfacing layer and the cover layer are respectively staggered at the welding starting position according to the welding procedure.
Compared with the prior art, the train wheel die holder welding device has the advantages that the structure is simple, novel and practical, the repairing process is safe and easy to operate, the welding quality is stable, the investment cost is low, the field actual requirements are met, the working efficiency is high, the maintenance cost is greatly reduced, the wheel rolling shutdown loss is reduced, the guarantee is provided for reasonable wheel assembly of various specifications, and the train wheel die holder welding device and the repairing process can provide scientific reference for repairing the special die holders of wheels which are researched and developed in future.
Drawings
The invention is further described with reference to the drawings and detailed description which follow:
FIG. 1 is a schematic diagram of a train wheel die holder welding device according to the present invention;
FIG. 2 is a schematic view of the ring heater according to the present invention;
FIG. 3 is a schematic view of a rotary support and a rotary apparatus for a die holder according to the present invention;
FIG. 4 is a schematic view of a die holder according to the present invention;
FIG. 5 is a schematic view of a build-up layer according to the present invention;
FIG. 6 is a schematic view of the welding direction in the present invention;
in the figure: 1. the die holder comprises a die holder rotating support 2, an annular heating device 3, a rotating device 4, a die holder supporting seat 5, a central ejector rod 6, a welding gun 7, a heater support 8, a limiting block 9, a gas pipeline 10, an annular pipeline 11, a burner 12, a gas pressure regulating valve 13, a die holder 14 and a wear surface.
Detailed Description
Example 1:
as shown in fig. 1 to 4, the welding device for the train wheel die holder of the invention comprises a die holder rotating support 1, an annular heating device 2, rotating equipment 3, a die holder supporting seat 4 and a welding gun 6; the annular heating device 2 comprises a gas pipeline 9, an annular pipeline 10 and a plurality of burners 11; the gas pipeline 9 is communicated with the annular pipeline 10, and the burner 11 is uniformly arranged on the inner side of the annular pipeline 10; the annular heating device 2 is fixedly arranged above the die holder rotating support 1 through a heater support 7; the top of the heater support 7 is welded and fixed with the bottom of the annular heating device 2, in order to facilitate connection between the bottom of the annular heating device 2 and the heater support 7, an adaptive annular plate can be fixedly arranged at the bottom of the annular pipeline 10, and then the annular plate is welded and fixed with the heater support 7, so as to ensure the stability of the annular heating device 2 during assembly and use, the lower part of the annular heating device penetrates through the top of the die holder rotating support 1 and is connected with the top of the die holder rotating support 1 in an up-down adjustable manner, the heater support 3 is provided with a limiting block 8, so that the height of a burner 11 in the annular heating device 2 can be conveniently adjusted by adjusting the distance of the bottom end of the heater support 7 extending out of the die holder rotating support 1 during application, the heating requirement of different height positions of the die holder 13 is met, and the limiting block 8 is used for limiting the upper or lower adjustment of the height of the heater support 7; the rotary equipment 3 is fixedly arranged at the central position of the top of the die holder rotary support 1, the rotary equipment 3 is provided with a rotary shaft, the top of the rotary shaft is provided with a die holder support seat 4 for placing a die holder 13, the die holder support seat 4 is positioned below the central position of the annular heating device 2, and the central position of the die holder support seat 4 is provided with a central ejector rod 5 for limiting and fixing the die holder 13; the welding gun 6 is arranged at the position of the annular heating device 2. In this embodiment, the rotating device 3 may be a variable frequency motor or a similar mechanism, and the rotating speed may be adjusted to meet the requirements of different welding speeds in practical application.
In this embodiment, in order to conveniently control the flame size sprayed from the burner 11, the gas pressure regulating valve 12 is disposed on the gas pipeline 9, and the pressure and the ventilation amount of the gas in the pipeline are regulated by the gas pressure regulating valve 12, so as to achieve different heating requirements of the die holder 13.
In this embodiment, the inner side of the annular pipe 10 is further provided with an insulating layer, which is provided to mainly prevent heat dissipation generated by combustion and ensure uniformity of heat at the heating position.
When the train wheel die holder welding device is applied, the die holder rotating support 1 is fixed, the rotating device 3 is installed on the die holder rotating support 1, the die holder supporting seat 4 is arranged at the top of the rotating device 3 and supports the die holder 13, the heater support 7 is installed on the top of the die holder rotating support 1, the limiting block 8 is fixed after the height is adjusted, the annular heating device 2 is welded and fixed on the top end of the heater support 7, then the annular heating device 2 is connected with the gas pipeline 9 and the gas pressure regulating valve 12, finally the welding gun 6 is fixed at the position to be welded of the die holder 13, the welding gun 6 can be fixed on the annular heating device 2 through a connecting piece, and a matched support can also be arranged for fixing.
Example 2:
as shown in fig. 1 to 6, in a process for repairing a train wheel die holder by adopting the welding device for a train wheel die holder in embodiment 1, the die holder 13 is made of z35# steel, the welding technical requirement is that a build-up layer is used for fusing a base metal, and a welding joint cannot have any welding defect, the process comprises the following steps:
step one, preparing before welding:
1.1 Preparing welding equipment; the welding equipment is divided into two types, namely a Nb-500P digital pulse gas shielded welder, a direct current positive connection is adopted, a matched welding material is a SWE71.1 phi 1.2mm flux-cored wire, and the shielding gas is carbon dioxide with the purity of more than or equal to 99.8 percent; secondly, using an HT400D digital control inversion type manual direct current welder, selecting an E5015 phi 3.2mm and phi 4.0mm welding rod as a matched welding rod, baking for 2 hours at 350-400 ℃ and then keeping constant temperature, and taking along with use;
1.2 Determining a region of a die holder to be welded, degreasing, removing moisture and an oxide layer on the region, firstly removing the greasy dirt and the moisture by using oxyacetylene flame, and then polishing and derusting by using a abrasive cloth or a nitrogrinding machine;
1.3 Placing the die holder 13 processed in step 1.2) on a die holder supporting seat 4, and fixing a welding gun of the digital pulse gas shielded welding machine as a fixing welding gun in a region of a position to be welded of the die holder;
1.4 Determining the technological parameters of die holder welding according to the welding equipment and the matched welding materials determined in the step 1.1); the welding process parameters are shown in the following table:
carbon dioxide gas shielded welding
Manual welding rod arc welding
1.5 Auxiliary facilities required by preparing welding, such as a heat preservation barrel, a sample plate, a thermometer, a magnifying glass and heat preservation cotton. Mask, glove, slag removing hammer, chisel, rasp, wire brush, sand paper, steel ruler, level bar, movable wrench, straight grinder and angle grinder. Wire pliers, hacksaw blades, labor protection articles (work clothes, shoes, caps, plain glasses);
step two, preheating and welding;
2.1 Introducing gas, which can be gas, natural gas and the like, into the gas pipeline 9, and preheating the die holder 13 to 150-200 ℃ from the outer side of the die holder 13 by utilizing each burner 11 of the annular heating device 2 in the embodiment by adopting a gas combustion heating mode; considering that the train wheel die holder is a large-scale steel casting, the special welding property of a local wear surface surfacing is overcome, a specially manufactured annular heating device 2 is adopted before the first layer of backing welding, the gas heating temperature change is regulated through a gas pressure regulating valve 12, the annular heating device 2 is installed and fixed on the outer side of the die holder 13 because the matched wear surface of the die holder 13 is welded on the inner side, the heating temperature of a burner is uniformly transferred from the outer side to the inner side, the preheating temperature is set to 150-200 ℃, the temperature is required to be uniformly increased by 50 ℃/h during the preheating, so that uneven high-temperature heating is avoided, microcracks are generated in the base metal of the large-scale steel casting of the integral die holder, and the integral die holder is heated because of the preheating, so that the local temperature difference stress can be reduced, the internal structure is improved, and the hardening structure is prevented from being generated or reduced;
2.2 Because the area of the die holder 13 to be welded is an annular fillet weld, a gradual upward welding mode is adopted, the bottommost layer is a base layer, the upper part of the base layer is a base layer and a cover layer, in the embodiment, the die holder 13 is welded with 6 layers which are respectively a base layer 1 ', a base layer 2', a base layer 3 ', a base layer 4', a base layer 5 'and a cover layer 6', in the practical application process, the number of layers to be welded can be determined according to the practical situation of the wearing surface on the inner side of the die holder 13, the rotating equipment 3 is started, the running direction and the running speed of the rotating equipment are regulated, the running speed of the die holder 13 placed on the rotating equipment is matched with the preset welding speed, then the base layer 1 'at the bottom of the area of the die holder 13 to be welded is welded by a fixed welding gun, the current is slightly larger during welding, the angle of the welding gun is required to meet the fusion of the bottom and the side surface of the wearing surface of the die holder 13, the welding line is not too thick, the short arc of an oblique triangle strip conveying method or the medium arc length of 15-22 mm is adopted, the width of the welding line is 8-10 mm, welding parameters can be set through a Nb-500P digital pulse gas shielded welder, after the end of the 1' welding line of the bottom layer is connected end to end, the rotating equipment 3 is closed, cleaning is carried out, polishing is carried out through an angle grinder and a 3-4 times magnifying glass is carried out to check whether the welding line has welding defects or not, if the welding defects such as cracks and air holes exist, the welding defects are carried out, the back chipping is carried out through a plasma gouging cutter, then the repair welding is carried out, manual electrode arc welding is adopted, the reverse type manual direct current welder is controlled digitally, the E5015 electrode is used for repair welding, the interlayer temperature is kept during repair welding, the interlayer temperature is preferably equal to the preheating temperature, and the welding line is checked again after repair welding, and no welding defects are ensured;
2.3 Welding the overlay layers 2 ', 3', 4 'and 5' by using the rotating equipment 3 again, carrying out arc welding on the overlay layers 2 ', 3', 4 'and 5' in turn by using a fixed welding gun for a reverse moon tooth shape strip conveying method short arc or 15-22 mm medium arc length, ensuring that each overlay layer keeps 8-10 mm wide, ensuring that each overlay layer is fused with a wearing surface of a die holder 13 when carrying out fillet weld overlay, and in the welding process, each overlay layer needs to be subjected to weld defect inspection after head-tail connection, particularly the joint of the head-tail connection is subjected to polishing inspection by adopting an angle grinder, if welding defects such as cracks and air holes exist, carrying out back chipping by adopting a plasma gouging cutter, carrying out repair welding by adopting manual electrode arc welding, carrying out repair welding by using an E5015 electrode by using a digital control reverse manual direct current welder, keeping interlayer temperature during repair welding, and checking the welding again after repair welding, thereby ensuring no welding defects;
2.4 Welding a top cover surface layer 6', welding by using a rotating device 3 through a fixed welding gun, wherein the width of a welding seam is 15-20 mm, the welding seam is required to cover a build-up welding layer and a die holder body, then performing omnibearing welding inspection, directly observing or searching for qualification by using a magnifying glass 3-4 times of magnifying glass, and dismantling the fixed welding gun after confirming no welding defect;
step three, post-welding treatment;
3.1 Starting the annular heating device 2 again, continuously heating the integral die holder to 350-450 ℃, keeping the temperature rising speed at 150 DEG/h to reduce the hardening degree, avoid embrittlement, eliminate the welding stress, wrapping the die holder with heat-insulating cotton, covering the die holder, and cooling to room temperature;
3.2 And (3) machining the welded integral die holder through a machine tool to enable the integral die holder to reach the assembly size, and completely meeting the requirements of the integral die holder and other rolling assemblies and die holder installation through on-site practical template inspection and acceptance and delivering for use.
In the embodiment, when the digital pulse gas shielded welder is matched with a flux-cored wire to weld a backing layer, the welding current is 260-280A, the arc voltage is 26-28V, the deposition speed is 90g/min, and when the overlay layer and the overlay layer are welded, the welding current is 280-320A, the arc voltage is 28-32V, and the deposition speed is 90-140 g/min; the method is characterized in that an E5015 electrode with the diameter of 3.2mm is adopted when a digital control inversion type manual direct current welder is matched with an electrode E5015 electrode in the process of repairing welding of a bottom layer, the welding current is 120-180A, the arc voltage is 23+/-1V, the welding speed is 15+/-1 cm/min, and the welding current is 180-220A, the arc voltage is 26+/-1V and the welding speed is 17+/-1 cm/min when the surfacing layer and the covering layer are subjected to repairing welding.
In this embodiment, as shown in fig. 6, the base layer, each weld overlay layer and the cover layer are respectively staggered at the welding starting positions according to the welding procedure, so that the effect of welding repair is prevented from being affected by one concentrated joint of each weld layer.
The above is only a preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions easily contemplated by those skilled in the art within the technical scope of the present invention should be covered by the present invention. Therefore, the protection scope of the present invention should be defined by the claims.
Claims (9)
1. The train wheel die holder repairing process is carried out by adopting a train wheel die holder welding device, wherein the train wheel die holder welding device comprises a welding gun (6), a die holder rotating support (1), an annular heating device (2), rotating equipment (3) and a die holder supporting seat (4); the annular heating device (2) is arranged and fixed above the die holder rotating support (1) through a heater support (7); the rotary equipment (3) is fixedly arranged at the central position of the top of the die holder rotary support (1), the top of the rotary equipment is provided with a die holder support seat (4), and the die holder support seat (4) is positioned below the central position of the annular heating device (2); the welding gun (6) is arranged at the position of the annular heating device (2), and is characterized by comprising the following steps:
step one, preparing before welding:
1.1 Preparing welding equipment; the welding equipment is divided into two types, namely a digital pulse gas shielded welder, a direct current positive connection is adopted, a matched welding material is selected as a flux-cored welding wire, and the shielding gas is carbon dioxide with the purity of more than or equal to 99.8%; secondly, digitally controlling the inverter type manual direct current welder, selecting an E5015 electrode as a matched electrode, baking, keeping constant temperature, and taking along with use;
1.2 Determining a region of a die holder to be welded, degreasing, removing moisture and an oxide layer on the region, firstly removing the greasy dirt and the moisture by using oxyacetylene flame, and then polishing and derusting by using a abrasive cloth or a nitrogrinding machine;
1.3 Placing the die holder processed in step 1.2) on a die holder supporting seat, and fixing a welding gun of the digital pulse gas shielded welding machine as a fixing welding gun in a region of a position to be welded of the die holder;
1.4 Determining the technological parameters of die holder welding according to the welding equipment and the matched welding materials determined in the step 1.1);
1.5 Preparing auxiliary facilities required by welding;
step two, preheating and welding;
2.1 Preheating the die holder to 150-200 ℃ from the outer side of the die holder by using an annular heating device;
2.2 Because the area of the die holder where the welding is needed is an annular fillet weld, starting a rotating device in a gradual upward welding mode, adjusting the running direction and the running speed of the rotating device, enabling the running speed of the die holder placed on the rotating device to be matched with the preset welding speed, then performing bottom layer clockwise welding on the area of the die holder where the welding is needed by a fixed welding gun, enabling the angle of the welding gun to meet the fusion of the bottom and the side face of a wear surface of the die holder during welding, adopting an oblique triangle strip method short arc or a middle arc length of 15-22 mm, enabling the width of the welding line to be 8-10 mm, closing the rotating device after the end of the welding line of the bottom layer is connected, cleaning and checking whether welding defects exist on the welding line or not, performing repair welding after back chipping welding by adopting a plasma gouging cutter, performing repair welding by adopting a manual welding rod through digital control inversion manual direct current welder, performing repair welding by adopting E5015 welding rod, maintaining the interlayer temperature during repair welding, and checking the welding line again after repair welding, and ensuring no welding defects;
2.3 Welding two layers and more than two surfacing layers by using rotating equipment again, performing welding of each surfacing layer by using a fixed welding gun in a short arc or 15-22 mm medium arc length by using an inverse moon-shaped strip conveying method, ensuring that each surfacing layer is kept at 8-10 mm width, ensuring that the surfacing layers are well fused with the abrasion surface of a die holder when fillet weld surfacing is performed, performing weld defect inspection on each surfacing layer after head-tail connection in the welding process, performing back gouging by using a plasma gouging cutter if welding defects such as cracks and air holes exist, performing repair welding by using a manual electrode arc welding by using an E5015 electrode by using a digital control inverse direct current manual welding machine, maintaining interlayer temperature during repair welding, and checking the weld again after repair welding to ensure no welding defects;
2.4 Welding a top cover surface layer, welding by using a rotating device through a fixed welding gun, wherein the width of a welding seam is 15-20 mm, the welding seam needs to cover a build-up welding layer and a die holder body, then performing omnibearing welding inspection, directly observing or looking up the welding seam qualified by using a magnifying glass 3-4 times, and dismantling the fixed welding gun after confirming that no welding defect exists;
step three, post-welding treatment;
3.1 Starting the annular heating device again, continuously heating the integral die holder to 350-450 ℃, wrapping with heat preservation cotton, covering the die holder, and cooling to room temperature;
3.2 And (3) machining the welded integral die holder through a machine tool to enable the integral die holder to reach the assembly size.
2. The train wheel die holder repair process according to claim 1, wherein the diameter of a flux-cored wire matched with the digital pulse gas shielded welder is 1.2mm, the welding current is 260-280A, the arc voltage is 26-28V, the deposition speed is 90g/min, the welding current is 280-320A, the arc voltage is 28-32V, and the deposition speed is 90-140 g/min when the overlay layer and the overlay layer are welded; the diameter of an E5015 electrode selected as a matched electrode of a digital control inversion type manual direct current welder is 3.2mm and 4.0mm, the temperature is kept after baking for 2 hours at 350-400 ℃ before use, the temperature is kept along with the use, the E5015 electrode with the diameter of 3.2mm is adopted when the bottom layer is subjected to repair welding, the welding current is 120-180A, the arc voltage is 23+/-1V, the welding speed is 15+/-1 cm/min, the E5015 electrode with the diameter of 4.0mm is adopted when the overlay layer and the cover layer are subjected to repair welding, the welding current is 180-220A, the arc voltage is 26+/-1V, and the welding speed is 17+/-1 cm/min.
3. The repairing process of train wheel mold base according to claim 1, wherein in the step 2.1), when the mold base is preheated from the outer side of the mold base by using each burner of the annular heating device, the temperature rising speed is 50 ℃/h; and 3.1) starting the annular heating device again to continuously heat the integral die holder, wherein the temperature rising speed is 150 ℃/h.
4. The repair process of a train wheel mold base according to claim 1, wherein the primer layer, each weld overlay layer and the cover layer are respectively staggered from each other at a welding start position according to a welding process.
5. The train wheel die holder repairing process according to claim 1, wherein the top of the heater support (7) is welded and fixed with the bottom of the annular heating device (2), the lower part of the heater support is connected with the die holder rotating support (1) in an up-down adjustable mode, and a limiting block (8) is arranged on the heater support (7).
6. A train wheel die holder repair process according to claim 1 or 2, characterized in that the annular heating device (2) comprises a gas pipeline (9), an annular pipeline (10) and a plurality of burners (11); the gas pipeline (9) is communicated with the annular pipeline (10), and the burner (11) is uniformly arranged on the inner side of the annular pipeline (10).
7. The train wheel die holder repair process according to claim 6, wherein a gas pressure regulating valve (12) is provided on the gas pipeline (9).
8. The train wheel die holder repair process according to claim 6, wherein an insulation layer is further provided on the inner side of the annular pipe (10).
9. The train wheel die holder repair process according to claim 1, wherein a center ejector rod (5) is provided at a center position of the die holder support base (4).
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| CN111266700B (en) * | 2020-03-30 | 2023-09-26 | 安徽马钢设备检修有限公司 | Welding device and repairing process for heat-resistant steel base of slow-cooling wheel |
| CN114654061B (en) * | 2022-04-20 | 2023-11-21 | 安徽马钢设备检修有限公司 | Welding heating device and repairing process for abrasion surface of base of wheel processing machine tool |
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