CN111037145A - Submerged arc welding molten drop transition physical simulation device and simulation method - Google Patents
Submerged arc welding molten drop transition physical simulation device and simulation method Download PDFInfo
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- CN111037145A CN111037145A CN201911413517.2A CN201911413517A CN111037145A CN 111037145 A CN111037145 A CN 111037145A CN 201911413517 A CN201911413517 A CN 201911413517A CN 111037145 A CN111037145 A CN 111037145A
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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
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
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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
- B23K9/18—Submerged-arc welding
Abstract
The invention discloses a submerged arc welding molten drop transition physical simulation device and a simulation method. The submerged arc welding molten drop transition physical simulation device comprises a liquid injection mechanism used for simulating molten metal at the tail end of a submerged arc welding wire, a gas injection mechanism used for simulating electric arc force borne by a molten drop, a high-speed shooting mechanism used for shooting a molten drop transition process and a recovery container used for recovering liquid. The physical simulation device for submerged arc welding molten drop transition simulates the molten drop transition phenomenon of high-temperature metal at the tail end of a welding wire in submerged arc welding by adopting the dripping phenomenon of normal-temperature liquid at the tail end of a column tube, and the protection cover is arranged for simulating the slag wall in the submerged arc welding, and the cavity in the protection cover is used for simulating the closed cavity of the submerged arc welding, so that the relation between the molten drop and the slag wall in the cavity can be clearly observed, reference is made for conjecturing the submerged arc welding molten drop transition form, scientific basis is provided for submerged arc welding electric arc physical theory research, and the problem that the submerged arc welding molten drop transition is invisible can be solved.
Description
Technical Field
The invention relates to the technical field of welding arc physics, in particular to a submerged arc welding molten drop transition physical simulation device and a simulation method.
Background
In submerged arc welding, the droplet transfer phenomenon cannot be directly observed because its arc is buried under the flux layer. Through the research on the submerged arc welding molten drop transition at home and abroad, the X-ray shooting in the last 50 th century jumps to the visible light high-speed shooting developed only in recent years, and through tests, the physical phenomenon in a submerged arc welding cavity is further known, but is far from real and comprehensive, and particularly in the aspect of simulation research, the research is still close to the blank at present.
The image quality of the early X-ray shooting is poor, and the X-ray has radiation damage and is not used at present. A thin-wall steel pipe is introduced into a high-speed photography technology which adopts visible light as backlight as a shooting channel, although the molten drop appearance at the tail end of a submerged-arc welding wire can be shot, the addition of the channel damages a closed cavity of the submerged-arc welding, so that the shooting result is not true; in addition, the image in the channel can not photograph the slag wall formed by the welding flux, so the photographing result is not complete.
Disclosure of Invention
The invention provides a submerged arc welding molten drop transition physical simulation device and a submerged arc welding molten drop transition physical simulation method, which aim to solve the technical problems that the shooting result is incomplete and not real enough.
The invention is realized by adopting the following technical scheme: a submerged arc welding molten drop transition physical simulation device comprises a liquid injection mechanism, a liquid injection mechanism and a liquid injection mechanism, wherein the liquid injection mechanism is used for melting metal molten drops at the tail end of a submerged arc welding wire; the liquid injection system comprises a liquid storage tank, a liquid guide pipe, a column pipe and a transparent protective cover, wherein liquid to be detected is contained in the liquid storage tank and used for simulating the metal molten drops, the liquid outlet end of the liquid storage tank is communicated with the liquid inlet end of the column pipe through the liquid guide pipe, a liquid control valve, a plunger pump and a liquid flowmeter are sequentially arranged on the liquid guide pipe along the direction from the liquid storage tank to the column pipe, the outer diameter of the column pipe is equal to the diameter of a submerged arc welding wire to be simulated, the tail end of the column pipe is provided with the protective cover, the inner part of the protective cover is a cavity, the tail end of the column pipe extends into the cavity, the other end of the protective cover opposite to the column pipe is provided with a through hole;
the gas injection mechanism is used for simulating electric arc force borne by the molten drop; the gas injection system comprises a gas pump, a gas guide pipe and a nozzle, wherein the output end of the gas pump is communicated with the input end of the gas guide pipe, a gas circuit control valve and a gas flowmeter are sequentially arranged on the gas guide pipe from the input end to the output end, the output end of the gas guide pipe is communicated with the gas inlet end of the nozzle, the nozzle is used for blowing gas upwards towards the liquid outlet end of the column pipe so as to simulate the upward electric arc force in electric arc welding, the gas outlet end of the nozzle penetrates through the through hole and extends into the cavity and is opposite to the tail end of the column pipe, and the gas outlet end of the nozzle is not in contact with the tail end of the column pipe and is used; and
and the high-speed photographing mechanism is used for photographing the metal droplet transition process.
As a further improvement of the above scheme, the high-speed photographing mechanism includes a backlight source, a high-speed camera and a control display, wherein the control display is in electrical signal connection with the high-speed camera and is used for setting the photographing rate and the exposure time of the high-speed camera and displaying a high-speed image of the growth and the falling of liquid droplets at the tail end of the column tube photographed by the high-speed camera, the backlight source and the high-speed camera are distributed on two opposite sides of the protective cover, and the backlight source is used for supplementing light for the high-speed camera.
Further, the high-speed photographing mechanism further comprises a backlight screen which is arranged between the backlight source and the protective cover and used for enlarging the lighting area of the backlight source.
As a further improvement of the scheme, the protective cover is hemispherical, the column tube is inserted from the center of the arc-shaped surface at the upper end of the protective cover, the through hole is formed in the center of the plane of the protective cover, and the diameter of the protective cover is 3-5 times of the outer diameter of the column tube.
Further, the end of the column tube is inserted into the cavity by 1-3 mm.
Furthermore, the aperture of the through hole is larger than the diameter of the nozzle, and the output end of the nozzle is inserted into the cavity by 1-2mm and is not contacted with the wall of the through hole.
As a further improvement of the scheme, the nozzle and the column tube are fixed through a clamp.
As a further improvement of the scheme, the air pump pulse type air pump has the frequency of 10-100 Hz.
As a further improvement of the above scheme, the submerged arc welding molten drop transition physical simulation device further comprises a recovery container which is arranged right below the protective cover and used for recovering the liquid to be measured.
The invention also discloses a simulation method of the submerged arc welding molten drop transition physical simulation device, which comprises the following steps:
s1: injecting the liquid to be detected into the column tube through a liquid guide tube, and adjusting the flow of the liquid to be detected to the required liquid flow through a liquid flow meter;
s2: supplying gas to the nozzle through the gas conduit, adjusting the gas flowmeter to the required gas flow, and observing the dropping condition of liquid drops at the tail end of the inner-layer column tube and the relation between the liquid drops and the protective cover;
s3: and shooting high-speed images of the liquid drop at the tail end of the column tube and the protective cover through a high-speed camera, and determining the relation between the liquid drop at the tail end of the column tube and the protective cover.
Advantageous effects
The invention relates to a submerged arc welding molten drop transition physical simulation device, which simulates the molten drop transition phenomenon of high-temperature metal at the tail end of a welding wire in submerged arc welding by adopting the dripping phenomenon of normal-temperature liquid at the tail end of a column tube, and the slag wall in the submerged arc welding is simulated by arranging a protective cover, and the inner cavity of the protective cover is used for simulating the closed cavity of the submerged arc welding, so that the relation between the molten drop in the cavity and the slag wall can be clearly observed, reference is made for conjecturing the submerged arc welding molten drop transition form, scientific basis is provided for submerged arc welding electric arc physical theory research, and the problem that the submerged arc welding molten drop transition is invisible can.
The liquid flow meter and the gas flow meter can conveniently control the liquid flow and the gas flow, so that the welding wire melting speed and the electric arc force can be simulated, the welding test workload can be reduced, the liquid flow and the gas flow can be accurately controlled, and the influence rule of the welding wire melting speed and the electric arc force on molten drop transition can be conveniently and quantitatively expressed.
The high-speed camera mechanism with the backlight is adopted to shoot the image of the submerged arc welding molten drop transition simulation experiment, so that the strong arc light interference and radiation of the welding experiment can be avoided, the accurate measurement of the characteristic values of the molten drop shape, the size, the transition frequency and the like is facilitated, the transition frequency in the physical simulation is low, the high-speed camera mechanism can be used for shooting the clear molten drop details, and the problem of insufficient shooting speed is solved.
Drawings
FIG. 1 is a schematic structural diagram of a submerged arc welding molten drop transition physical simulation device.
In the figure: 10-a liquid storage tank; 11-a liquid conduit; 12-a liquid control valve; 13-a plunger pump; 14-column tube; 15-a protective cover; 16-a liquid flow meter; 20-an air pump; 21-a gas conduit; 22-a gas path control valve; 23-a nozzle; 24-a gas flow meter; 30-backlight light source; 31-a high-speed camera; 32-control the display; 33-a backlight screen; 40-recovery vessel.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
The physical simulation device for submerged arc welding molten drop transition comprises a liquid injection mechanism for simulating molten metal at the tail end of a submerged arc welding wire, a gas injection mechanism for simulating electric arc force borne by a molten drop, a high-speed photographing mechanism for photographing the molten drop transition process and a recovery container 40 for recovering liquid. The dripping phenomenon of the normal temperature liquid at the tail end of the column tube is adopted to simulate the molten drop transition phenomenon of the high temperature metal at the tail end of the welding wire in submerged arc welding, and the submerged arc welding device is simple in structure and convenient to operate.
The liquid injection mechanism includes a liquid reservoir tank 10, a liquid conduit 11, a liquid control valve 12, a plunger pump 13, a column tube 14, a transparent boot 15, and a liquid flow meter 16. The liquid storage tank 10 is filled with liquid to be detected, the liquid to be detected is used for simulating metal molten drops, the liquid to be detected can be a liquid outlet end of the liquid storage tank 10 and a liquid inlet end of a column tube 14 and is communicated through a liquid guide pipe 11, a liquid control valve 12, a plunger pump 13 and a liquid flowmeter 16 are sequentially arranged on the liquid guide pipe 11 and along the direction from the liquid storage tank 10 to the column tube 14, a protective cover 15 is arranged at the tail end of the column tube 14, a cavity is formed in the protective cover 15, the tail end of the column tube 14 extends into the cavity, a through hole is formed in the protective cover 15 relative to the other end of the column tube 14, the rest parts of the protective cover 15 except the through hole are kept closed. Wherein the liquid control valve 12 is used for controlling the on-off of the liquid conduit 11, and the plunger pump 13 is used for regulating the liquid pressure in the liquid conduit 11.
The flow of the liquid to be measured entering the column tube 14 is controlled by the liquid flow meter 16, so that the melting speed of the submerged arc welding wire is simulated, and the larger the liquid flow is, the larger the speed is, and the smaller the flow is, the smaller the speed is. Through adding different solutes into the liquid storage tank 10 and then mixing, liquids with different surface tension coefficients and viscosities can be obtained, so that molten steel with different components at different temperatures is simulated, the influence law of the tension coefficients and the viscosities on molten drop transition is conveniently researched, and a large amount of metal welding wires with different components are prevented from being purchased or produced. The liquid to be measured can be a solid substance which can be melted by heating, such as paraffin, and a heating device with adjustable power is arranged on the outer side of the column tube 14 to melt the paraffin, so that the molten drop transition process is simulated; the liquid to be measured can also have a viscosity coefficient of 1-10 multiplied by 10-3Pa · s, such as milk.
The outer diameter of the column tube 14 is equal to the diameter of a submerged arc welding wire to be simulated, the material of the column tube 14 can be glass or plastic, the column tube 14 is fixed by a clamp and then vertically placed, and liquid to be measured is introduced into the column tube to simulate molten metal.
The protective cover 15 is hemispherical, the diameter of the protective cover is 3-5 times of the outer diameter of the column tube 14, the material of the protective cover can be transparent glass or plastic, the protective cover is used for simulating a slag wall in submerged arc welding, and a cavity in the protective cover 15 is a submerged arc welding cavity, so that the relation between molten drops in the cavity and the slag wall can be clearly observed, reference is made for conjecturing a submerged arc welding molten drop transition form, scientific basis is provided for submerged arc welding electric arc physical theory research, and the problem that submerged arc welding molten drop transition is invisible can be solved. The column tube 14 is inserted 1-3mm from the center of the upper end arc surface of the protective cover 15, and the through hole is arranged at the center of the plane of the protective cover 15.
The gas injection mechanism includes a gas pump 20, a gas conduit 21, a nozzle 23, and a gas flow meter 24. The air pump 20 is a pulsating air pump, so that the electric arc in real welding can be better simulated. The output end of the air pump 20 is communicated with the input end of the gas guide pipe 21, the gas guide pipe 21 is provided with a gas path control valve 22, the output end of the gas guide pipe 21 is communicated with the gas inlet end of a nozzle 23, the nozzle 23 is used for blowing gas upwards towards the liquid outlet end of the column tube 14 so as to simulate the upward electric arc force in electric arc welding, and the gas outlet end of the nozzle 23 is not contacted with the tail end of the column tube 14.
The nozzle 23 is connected with the air pump 20 through the air conduit 21, is fixed by a clamp and then is arranged right below the column tube 14, the upper end of the nozzle 23 penetrates through the through hole and is inserted into the cavity by 1-2mm, but is not connected with the wall of the through hole, namely, the central aperture of the bottom of the protective cover 15 is larger than the diameter of the nozzle 23, so that the liquid in the hemispherical cover can flow out to the recovery container 40.
The high-speed imaging mechanism includes a backlight source 30, a high-speed camera 31, a control display 32, and a backlight screen 33. The shooting speed of the high-speed camera 31 is 500-5000fps, the display 32 is controlled to be in electrical signal connection with the high-speed camera 31 and used for setting the shooting speed and the exposure time of the high-speed camera 31 and displaying a high-speed image of growth and falling of liquid drops at the tail end of the column tube 14 and inside the protective cover 15 shot by the high-speed camera 31, the backlight source 30 and the high-speed camera 31 are distributed on two opposite sides of the protective cover 15, in a real submerged arc welding test, shadow images of welding wires and molten drops are shot by the high-speed camera 31, and the backlight screen 33 is used for obtaining an illuminated area with more uniform brightness and increased area, so that the shooting definition is improved, and in order to weaken the interference of strong arc light, the backlight source 30 is used for light supplement. The backlight screen 33 is disposed between the backlight source 30 and the protective cover 15.
In the physical simulation of the present invention, there is no strong arc, and a high-speed photography technique is adopted, so that light is needed to supplement when the shooting speed is high (such as more than 1000fps), and the backlight source 30 plays a role of light supplement. The molten drop transition frequency of the real submerged arc welding is high (reaching dozens to hundreds of Hz), in order to shoot more molten drop transition details, a high shooting speed (2000-5000 fps, even higher) is needed, the transition frequency of the physical simulation is low (0.3-100 Hz), the details can be shot by adopting a low shooting speed (500-1000 fps), and the problem of the shooting speed does not exist in the physical simulation of the invention.
The invention also discloses a simulation method of the submerged arc welding molten drop transition physical simulation device.
The first step is as follows: the liquid control valve 12 and the plunger pump 13 are opened, the liquid to be measured is injected into the column tube 14 through the liquid guide tube 11, and the flow rate of the liquid to be measured is adjusted to a desired liquid flow rate by the liquid flow meter 16.
The second step is that: the air pump 20 and the air path control valve 22 are opened, air is supplied to the nozzle 23 through the air conduit 21, the relationship between the liquid drop dropping condition at the tail end of the column tube 14 and the protective cover 15 is observed, the gas flowmeter 24 is adjusted, and the required gas flow is obtained, so that the influence rules of different flow sizes and the liquid drop dropping condition, namely the influence rules of the upward electric arc force and the molten drop dropping condition of different sizes are obtained.
The third step: turning on the backlight source 20 and the high-speed camera 31, setting a shooting speed and an exposure time on the control display 32, shooting a high-speed image of the growth and the falling of the liquid drops at the tail end of the column tube 14 and a high-speed image of the protective cover 15, then watching the high-speed image in computer software, and determining the relationship between the liquid at the tail end of the column tube 14 and the protective cover 15, thereby presuming the relationship between the metal liquid and the slag wall in the submerged arc welding and solving the difficult problem that the molten drop transition of the submerged arc welding is invisible.
The invention simulates the welding wire melting speed under different welding parameters by adjusting the liquid flow, and simulates the upward electric arc force in submerged arc welding by adjusting the gas flow, thereby simulating different forms of molten drop transition forms in the submerged arc welding. And simple structure, convenient operation.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents and improvements made within the spirit and principle of the present invention are intended to be included within the scope of the present invention.
Claims (10)
1. A submerged arc welding molten drop transition physical simulation device is characterized by comprising:
the liquid injection mechanism is used for submerged-arc welding of molten metal droplets at the tail end of the welding wire; the liquid injection system comprises a liquid storage tank (10), a liquid guide pipe (11), a column pipe (14) and a transparent protective cover (15), liquid to be detected is contained in the liquid storage tank (10) and used for simulating metal molten drops, the liquid outlet end of the liquid storage tank (10) is communicated with the liquid inlet end of the column pipe (14) through the liquid guide pipe (11), a liquid control valve (12), a plunger pump (13) and a liquid flowmeter (16) are sequentially arranged on the liquid guide pipe (11) and along the direction from the liquid storage tank (10) to the column pipe (14), the outer diameter of the column pipe (14) is equal to the diameter of a submerged arc welding wire to be simulated, the protective cover (15) is arranged at the tail end of the column pipe (14), a cavity is arranged inside the protective cover (15), the tail end of the column pipe (14) extends into the cavity, and a through hole is formed in the protective cover (15) relative to the other, and the rest of the protective cover (15) is kept closed except the through hole;
the gas injection mechanism is used for simulating electric arc force borne by the molten drop; the gas injection system comprises a gas pump (20), a gas guide pipe (21) and a nozzle (23), wherein the output end of the gas pump (20) is communicated with the input end of the gas guide pipe (21), a gas path control valve (22) and a gas flowmeter (24) are sequentially arranged on the gas guide pipe (21) from the input end to the output end, the output end of the gas guide pipe (21) is communicated with the gas inlet end of the nozzle (23), the nozzle (23) is used for blowing gas upwards towards the liquid outlet end of the column pipe (14) so as to simulate the upward electric arc force in electric arc welding, the gas outlet end of the nozzle (23) penetrates through the through hole and extends into the cavity and is opposite to the tail end of the column pipe (14), and the gas outlet end of the nozzle (23) is not in contact with the tail end of the column pipe (14) and is used for; and
and the high-speed photographing mechanism is used for photographing the metal droplet transition process.
2. The submerged arc welding droplet transfer physical simulation device of claim 1, characterized in that: the high-speed photographic mechanism comprises a backlight source (30), a high-speed camera (31) and a control display (32), wherein the control display (32) is connected with the high-speed camera (31) through electric signals and used for setting the shooting speed and the exposure time of the high-speed camera (31) and displaying a high-speed image of the growth and the falling of liquid drops at the tail end of the column tube (14) shot by the high-speed camera (31), the backlight source (30) and the high-speed camera (31) are distributed on two opposite sides of the protective cover (15), and the backlight source (30) is used for supplementing light for the high-speed camera (31).
3. The submerged arc welding droplet transfer physical simulation device of claim 2, characterized in that: the high-speed photographing mechanism further comprises a backlight screen (33) which is arranged between the backlight source (30) and the protective cover (15) and used for enlarging the lighting area of the backlight source (30).
4. The submerged arc welding droplet transfer physical simulation device of claim 1, characterized in that: the safety cover (15) are hemispherical, the column tube (14) is inserted from the center of the arc-shaped surface at the upper end of the safety cover (15), the through hole is formed in the center of the plane of the safety cover (15), and the diameter of the safety cover (15) is 3-5 times of the outer diameter of the column tube (14).
5. The submerged arc welding droplet transfer physical simulation device of claim 4, characterized in that: the tail end of the column tube (14) is inserted into the cavity by 1-3 mm.
6. The submerged arc welding droplet transfer physical simulation device of claim 4, characterized in that: the aperture of the through hole is larger than the diameter of the nozzle (23), and the output end of the nozzle (23) is inserted into the cavity by 1-2mm and is not contacted with the wall of the through hole.
7. The submerged arc welding droplet transfer physical simulation device of claim 1, characterized in that: the nozzle (23) and the column tube (14) are fixed through a clamp.
8. The submerged arc welding droplet transfer physical simulation device of claim 1, characterized in that: the air pump (20) is a pulsating air pump, and the frequency is 10-100 Hz.
9. The submerged arc welding droplet transfer physical simulation device of claim 1, characterized in that: the submerged arc welding molten drop transition physical simulation device further comprises a recovery container (40) which is arranged under the protection cover (15) and used for recovering the liquid to be detected.
10. A simulation method of a submerged arc welding droplet transfer physical simulation apparatus according to any one of claims 1 to 9, characterized in that: the specific method comprises the following steps:
s1: injecting the liquid to be detected into the column tube (14) through the liquid guide tube (11), and adjusting the flow rate of the liquid to be detected to the required liquid flow rate through the liquid flowmeter (16);
s2: supplying gas to a nozzle (23) through a gas conduit (21), adjusting a gas flow meter (24) to a required gas flow rate, and observing the dropping condition of liquid drops at the tail end of the inner-layer column tube (14) and the relation between the liquid drops and a protective cover (15);
s3: a high-speed camera (31) is used for shooting a high-speed image of the liquid drop at the tail end of the column tube (14) and the protective cover (15) to determine the relation between the liquid drop at the tail end of the column tube (14) and the protective cover (15).
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Address after: 030600 North of No. 7 Road of Huitong Industrial Park, Jinzhong Development Zone, Jinzhong Comprehensive Reform Demonstration Zone, Shanxi Province Patentee after: Zhonggang Stainless Steel Pipe Industry Technology Shanxi Co.,Ltd. Address before: 030600 North of No. 7 Road of Huitong Industrial Park, Jinzhong Development Zone, Jinzhong Comprehensive Reform Demonstration Zone, Shanxi Province Patentee before: SINOSTEEL STAINLESS STEEL PIPE TECHNOLOGY SHANXI CO.,LTD. |