CN111069856A - Assembling welding and shape and position size control method for 5-meter-diameter cylinder section flange - Google Patents
Assembling welding and shape and position size control method for 5-meter-diameter cylinder section flange Download PDFInfo
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- CN111069856A CN111069856A CN201911384329.1A CN201911384329A CN111069856A CN 111069856 A CN111069856 A CN 111069856A CN 201911384329 A CN201911384329 A CN 201911384329A CN 111069856 A CN111069856 A CN 111069856A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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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
- B23K31/003—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 controlling of welding distortion
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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
- B23K31/02—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 soldering or 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
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/04—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work
- B23K37/053—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work aligning cylindrical work; Clamping devices therefor
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Abstract
The invention provides an assembly welding and form and position size control method of a 5-meter-diameter cylinder section flange, which comprises the steps of mechanically perforating a single target cylinder section needing to be welded with the flange and welding the flange before a closed storage box is formed. According to the method for assembling, welding and controlling the shape, position and size of the 5-meter-diameter cylinder section flange, the manual hole opening of the storage box cylinder section is improved from the manual hole opening in the whole box state to the mechanical hole opening in the single cylinder section state, the hole opening precision is improved, and a foundation is laid for ensuring the welding quality and reducing the welding deformation subsequently.
Description
Technical Field
The invention belongs to the technical field of welding of rocket fuel storage tanks, and particularly relates to an assembly welding and form and position size control method of a 5-meter-diameter cylinder section flange.
Background
The new generation carrier rocket undertakes the tasks of lunar exploration and deep space exploration, and the diameter of the fuel storage tank is phi 5000mm, so that the fuel storage tank is used for filling, storing and conveying fuel and bearing all structural loads in the rocket body flying process. The storage tank is formed by welding two hemispherical tank bottoms and a plurality of middle barrel sections in a splicing way, the thickness of the tank bottoms and the barrel sections is within the range of 3-10mm, holes are formed in the tank bottoms or the middle barrel sections for welding flanges, the flanges are distributed on the tank bottom structure in general conditions, but due to structural requirements, part of the flanges are distributed on the barrel sections, a plurality of flanges are required to be assembled and welded at special designated positions of the middle barrel sections, the flanges are in an I shape, the lower ends of the I shape are in butt welding with the holes of the barrel sections, the diameter of the welding ends of the flanges is 300mm, the thickness of a welding area is the same as that of the barrel sections, and the overall structure is shown in figure 1. Generally, the assembly welding sequence of the fuel storage tank is that a first tank bottom and a first cylinder section are welded in an involutive mode, then the first cylinder section and a second cylinder section are welded in an involutive mode, and the like until all the cylinder sections are welded in an involutive mode, then the other tank bottom and the last cylinder section are welded in an involutive mode to form a closed storage tank, after the storage tank is welded, a hole is formed in the cylinder section manually, the size of the hole is matched with that of the hole in a rubbing mode, a tool is used for fixing the to-be-welded part of the flange and the cylinder section, and welding is completed manually.
The cylinder section has large structure, thin wall and weak rigidity, if the cylinder section is mechanically perforated externally, the inner side of the cylinder section is a closed space, the cylinder section internal supporting device cannot be installed, the whole storage box is difficult to clamp, and further the mechanical perforation cannot be completed, and only manual perforation can be adopted. And the manual tapping process is that a drill bit is used for punching in a whole circle, residual materials in the middle are taken down, the size of the inner side of a tapping circle is trimmed by the drill bit and a scraper, the precision is difficult to guarantee, the maximum difference value of the tapping roundness can reach 1mm, the assembly condition of the flange and the cylinder section at the opposite time is poor, the welding quality is affected, stress concentration is easy to occur on a welding line, and the bearing failure risk of the storage tank is further caused.
In addition, manual welding is greatly influenced by the skill of a welder, and the welding quality has great fluctuation. The welding seam belongs to a closed annular welding seam, the stress of the structure is complex, the stress of the welding seam is uneven in the manual welding process, the restraint degree of a welding joint is large, the residual stress generated after welding is also large, the deformation near the welding seam is large, the shape and position size of the flange at the position is further influenced, and the work of subsequent butt joint of pipelines is difficult to realize.
Meanwhile, after the welding heat input is effectively controlled, the deformation amount near the welding seam is small, but the deformation is still visible visually. The residual stress of the welding line cannot be avoided, the force can cause the buckling deformation to occur on the cylinder section close to the welding line, the deformation zone is closer to the edge of the cylinder section, the roundness of the edge of the cylinder section is further influenced, the assembly quality is influenced during the subsequent butt welding of the cylinder section and the cylinder section, the welding quality cannot be guaranteed, and the difference value between the deformed actual profile and the theoretical profile reaches 5-10 mm.
Disclosure of Invention
In view of the above, the invention aims to provide a method for assembling, welding and controlling the shape, position and size of a 5-meter-diameter cylinder section flange, so as to overcome the defects of the prior art, the manual hole opening of the cylinder section of the storage tank is improved from the manual hole opening in the whole tank state to the mechanical hole opening in the single cylinder section state, the hole opening precision is improved, and a foundation is laid for ensuring the welding quality and reducing the welding deformation in the follow-up process.
In order to achieve the purpose, the technical scheme of the invention is realized as follows:
a method for assembling, welding and controlling the shape, position and size of a flange of a 5-meter-diameter cylinder section comprises the steps of mechanically drilling a hole on a single target cylinder section to be welded with the flange and welding the flange before a closed storage tank is formed.
Preferably, the method for mechanically drilling the hole on the single target cylinder section needing the welding flange comprises the following steps: placing the cylinder section on a platform in a lying posture, rounding the cylinder section by using an internal bracing device, and drilling holes at a specified position outside the cylinder section by using a milling cutter;
preferably, when the hole is opened, a method is adopted in which a hole smaller than the target hole diameter by a certain length range is opened at a specified position, and then the milling diameter is gradually enlarged outwards until the target opening diameter is reached.
Preferably, the inner supporting device adopts a 5M-level storage box sealing circular seam inner supporting device disclosed in Chinese patent application CN 201510065305.5.
Preferably, the standard of using the internal supporting device to support the cylinder section into a circle is to tightly support the inner side of the cylinder section and ensure that the roundness of the whole circle of the outer side of the cylinder section is within 0.2 mm.
Preferably, the method of welding the flange comprises the steps of:
1) vertically hoisting the perforated cylinder section to a bracket, enabling the perforated position to face towards the right lower side, assembling a flange at the perforated position, and fixing the cylinder section and a flange welding area by using a tool;
2) after the direct current positioning welding is carried out by adopting the sectional positioning, the backing welding and the cover surface welding are carried out by adopting a mode of symmetrically distributing the lap joint quantity;
3) and releasing residual stress for the welding seam by adopting a knocking shape correction method, and recovering the molded surface of the product.
Preferably, in the step 1), the cylinder section and the flange welding area are assembled in an interference fit mode, the joint is completely closed without a gap, and the gap is within 0.2 mm.
Preferably, in the step 1), the fixture for fixing the cylinder section and the flange welding area comprises a cylinder section pressing beam and a plurality of cylinder section pressing rods arranged on the cylinder section pressing beam, the cylinder section pressing rods are distributed at intervals along one circle of the periphery of the flange welding area, and the tail ends of the cylinder section pressing rods are attached with cylinder section pressing discs; the cylinder section pressing disc is annular and is positioned at the periphery of the flange welding area, and the lower end of the cylinder section pressing disc is tightly attached to the inner surface of the cylinder section; the cylinder section pressing beam is detachably fixed on the bracket;
preferably, in the step 1), the bracket is provided with an annular suspension groove for forming welding leakage in the welding process.
Preferably, in the step 2), the method for performing the dc tack welding by using the segmented tack welding comprises the following steps: and respectively rotating the welding gun to two positions of 120 degrees and 240 degrees, performing direct current positioning welding, wherein the welding length of each section is about 40-50mm, and positioning the whole circle of involution.
Preferably, in the step 2), the method for performing backing welding and cover surface welding by adopting a mode of symmetrically distributing overlapping amount comprises the following steps: the backing welding is started from 0 degree, and after one circle of welding, the welding is overlapped to the range of 20-90 degrees; the arc is started from 180 degrees in the cover surface welding process, and after one circle of welding, the cover surface is overlapped to the range of 200-270 degrees, so that the distribution of heat input is effectively controlled, and the welding deformation is reduced.
Preferably, in the step 3), a method for releasing residual stress of the weld seam by adopting a knocking shape correction method comprises the following steps: heating the welding seam area, extruding the deformation convex area, supporting the front side of the welding seam, knocking the back of the welding seam, scraping a hardened layer of the welding seam, and knocking and correcting the shape of the whole circle step by step until the deformation convex area at the periphery of the welding seam is recovered;
preferably, the temperature of the heating weld zone is controlled to be 60-100 ℃.
Preferably, the method of forming a closed tank comprises the steps of:
(1) the first box bottom and the first cylinder section are welded in a butt joint mode;
(2) the first cylinder section and the second cylinder section are welded in a butt joint mode, and the rest is done in the same way until all the cylinder sections are welded in a butt joint mode;
(3) and the other box bottom and the last cylinder section are welded in a matching way to form a closed storage box.
Compared with the prior art, the assembling, welding and form, position and size control method for the 5-meter-diameter cylinder section flange has the following advantages:
(1) the storage tank barrel section is improved from manual hole opening in the whole tank state to mechanical hole opening in the single barrel section state, hole opening precision is improved, and a foundation is laid for ensuring welding quality and reducing welding deformation subsequently.
(2) The welding process adopts a method of sectional positioning and symmetrical distribution of lap joint quantity to effectively control welding heat input and welding deformation.
(3) Aiming at welding deformation, a method of knocking weld joint shape correction is adopted to recover the deformed profile, and the difference value between the actual profile and the theoretical profile of a product can be controlled within 3 mm.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 is a schematic view of the overall construction of a fuel tank;
FIG. 2 is a schematic diagram of a mechanical hole drilling front view simple structure of a five-axis boring and milling machine;
FIG. 3 is a schematic diagram of a top view simple structure of a mechanical boring and milling machine with five shafts;
FIG. 4 is a side view of a simple structure of the welding of the barrel section and the flange;
FIG. 5 is a simplified schematic front sectional view of a barrel section and flange assembly weld;
FIG. 6 is a schematic view of a segmented tack weld;
FIG. 7 is a schematic view of a symmetrically distributed weld lap;
FIG. 8 is a schematic diagram of a sizing process;
fig. 9 is a flow chart of a scheme of mechanically drilling a hole in a single target cylinder section and welding a flange in the method for assembling, welding and controlling the form, position and size of the 5-meter-diameter cylinder section flange.
Description of reference numerals:
1-box bottom; 2-barrel section; 3-a flange; 4-an internal bracing device; 401-support mechanism C; 402-inner support ring a; 403-outer support ring B; 5-a device platform; 6-positioning blocks; 7-milling cutter; 8-a milling mechanism; 9-a barrel section compression beam; 10-a welding gun; 11-a barrel section pressing rod; 12-a barrel section pressing disc; 13-a carrier; 14-flange gland nut; 15-flange hold down bar; 16-a suspension groove; 17-rotating the disc; 18-connecting bolts; 19-cross beam.
Detailed Description
It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict.
In the description of the present invention, it is to be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like, indicate orientations or positional relationships based on those shown in the drawings, and are used only for convenience in describing the present invention and for simplicity in description, and do not indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and thus, are not to be construed as limiting the present invention. Furthermore, the terms "first", "second", etc. are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first," "second," etc. may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless otherwise specified.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art through specific situations.
The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
The cylinder section has large structure, thin wall and weak rigidity, if the cylinder section is mechanically perforated externally, the inner side of the cylinder section is a closed space, the cylinder section internal supporting device cannot be installed, the whole storage box is difficult to clamp, and further the mechanical perforation cannot be completed, and only manual perforation can be adopted. And the manual tapping process is that a drill bit is used for punching in a whole circle, residual materials in the middle are taken down, the size of the inner side of a tapping circle is trimmed by the drill bit and a scraper, the precision is difficult to guarantee, the maximum difference value of the tapping roundness can reach 1mm, the assembly condition of the flange and the cylinder section at the opposite time is poor, the welding quality is affected, stress concentration is easy to occur on a welding line, and the bearing failure risk of the storage tank is further caused.
In order to overcome the defects, after the characteristics of the structure of the storage tank are analyzed, the assembling and welding and form and position size control method of the 5-meter-diameter cylinder section flange adjusts the assembling and welding sequence of the storage tank, firstly, a cylinder section 2 needing to be welded with the flange 3 is mechanically perforated, the flange 3 is welded, then, a first tank bottom 1 and a first cylinder section 2 are welded in an involutory mode, then, the first cylinder section 2 and a second cylinder section 2 are welded in an involutory mode, the analogy is carried out until all the cylinder sections 2 are welded in the involutory mode, and finally, the other tank bottom 1 and the last cylinder section 2 are welded in an involutory mode to form the closed storage tank. The method that the flange 3 is mechanically perforated and welded on the single cylinder section 2 and then the welded storage box is assembled is adopted, so that the perforating precision can be ensured, the precision when the perforated part of the cylinder section 2 is assembled and matched with the flange 3 is ensured, and the welding quality is further ensured.
FIG. 9 is a flow chart of a scheme of mechanically drilling a hole on a single target cylinder section and welding a flange in the method for assembling, welding and controlling the shape, position and size of the 5-meter-diameter cylinder section flange. As shown in fig. 9, the process is as follows:
the mechanical tapping process of the individual barrel sections is as follows:
the inner supporting device 4 in a container sealing circular seam inner supporting device in a 5M-level container sealing circular seam inner supporting device (application number 201510065305.5, granted notice number 2017.10.10, granted notice number CN104646908B) applied by the unit at 2015 2, 6 days supports the cylinder section 2, adjusts the supporting mechanism C401 to enable the supporting block to withdraw 30-50mm towards the circle center, lifts the cylinder section 2 to the equipment platform 5 in a flat lying posture, the outer side of the cylinder section 2 is attached to 4 positioning blocks 6, adjusts the supporting mechanism C401 to enable the supporting block to be ejected outwards until the supporting block is attached to the inner side of the cylinder section 2 and tightly supported, and the roundness of the whole circle of the outer side of the cylinder section 2 is controlled within 0.2 mm.
And calling a milling program, and using a milling cutter 7 to open a hole at a specified position, wherein the diameter of the hole is within the range of 100-300mm according to requirements. When the hole is opened, a method of firstly opening a hole with a certain length range smaller than the target hole diameter at a specified position and then gradually expanding the milling diameter outwards until the target hole opening diameter is reached is adopted. Taking the opening diameter of a as an example (the diameter of the opening can also be understood as a), firstly milling a circle with the diameter of (a-10) mm, taking down the residual material, and then gradually expanding the milling diameter outwards, and milling according to the opening diameters of (a-8), (a-6), (a-4), (a-2) and a, and gradually feeding to ensure the accuracy of the opening, wherein the error can be controlled within the range of +/-0.1 mm. And after the hole is opened, adjusting the supporting mechanism C401 to enable the supporting block to withdraw 30-50mm towards the circle center, and hoisting the cylinder section 2 to be put on the shelf. The equipment for mechanically drilling the cylinder section 2 is a five-axis boring and milling machine, the whole structure is shown in figures 2 and 3, the equipment comprises a milling mechanism 8, an equipment platform 5, an inner support device 4 and a positioning block 6, the milling mechanism 8 is provided with a milling cutter 7, the tapping work on the cylinder section 2 can be realized, the cylinder section 2 is arranged on the equipment platform 5, the cylinder section 2 can be ensured to be in a horizontal state, 4 positioning blocks 6 can ensure that when the cylinder section 2 is hoisted to the equipment platform 5, the cylinder section 2 and the inner supporting device 4 are concentric, which is convenient for the subsequent supporting and milling work, the inner supporting device 4 is 2 sets, which respectively supports the upper end and the lower end of the cylinder section, the inner supporting device 4 is composed of an inner supporting ring A402, an outer supporting ring B403 and a supporting mechanism C401, the supporting mechanism C401 is composed of a plurality of supporting blocks and a jacking mechanism, the length of the jacking mechanism connected with the supporting block can be adjusted, so that the supporting block can tightly support or loosen the barrel section 2.
After the hole of the cylinder section 2 is opened, firstly, the cylinder section 2 is lifted in a lying posture by using a hanging belt, the cylinder section 2 is turned over in the air to be in a vertical state, the hole is turned right below, the cylinder section 2 is placed on a bracket 13 (the bracket 13 is a support with an upper surface being an inwards concave cambered surface, the diameter of the inwards concave cambered surface is equal to the outer diameter of the cylinder section 2, the specific structure is shown in figures 4 and 5), the cylinder section 2 is attached to the upper surface of the bracket 13, a cylinder section pressing disc 12 is placed on the inner side of the cylinder section 2, the cylinder section pressing disc 12 is concentric with the hole opening circle of the cylinder section 2, a cylinder section pressing beam 9 is abutted to the bracket 13 and is screwed by using a connecting bolt 18, a circle of 16 cylinder section pressing rods 11 on the cylinder section pressing beam 9 is rotated to prop against the cylinder section pressing disc 12, so that the cylinder; then placing the flange 3 above the opening of the cylinder section 2, knocking the joint of the flange 3 by using a hammer to ensure that the flange 3 and the opening of the cylinder section 2 are assembled in an interference fit manner, the joint is completely gapless, the gap is controlled within 0.2mm, and fixing the flange 3 by using a flange compression nut 14 and a flange compression rod 15; and finally, adjusting the height and the extension length of the cross beam 19 to enable the welding gun 10 to move above the joint of the flange 3 and the cylinder section 2, and adjusting the rotating speed of the rotating disk 17 to enable the welding gun 10 to complete annular welding. The assembly welding of the barrel section 2 and the flange 3 is shown in fig. 4 and 5, and the bracket 13 is provided with an annular suspension groove 16 for forming a weld leakage in the welding process, which is also called suspension welding; the cylinder section pressing beam 9, the cylinder section pressing rod 11 and the cylinder section pressing disc 12 are used for fixing and pressing the cylinder section 2; the flange pressing rod 15 and the flange pressing nut 14 are used for fixing the pressing flange 3; 4 connecting bolts 18 are used for connecting the bracket 13 and the barrel section pressing beam 9; the cross beam 19 is fixed on the ground, can move up and down, front and back, and is used for adjusting the position of the welding gun 10 so that the welding gun 10 can move to the upper part of the involution part for welding, and the rotating disk 17 arranged on the cross beam 19 can rotate at a constant speed and is used for realizing the welding work of the annular welding seam by the welding gun 10.
The welding seam of the flange 3 is a closed annular welding seam, and compared with manual welding, automatic welding can ensure stable welding heat input, uniform and consistent welding seams, small welding deformation and high welding quality. The welding process adopts a welding mode of firstly performing direct current bottoming and then performing alternating current capping, wherein the direct current bottoming refers to non-consumable electrode inert gas shielded welding, the non-consumable electrode uses a tungsten electrode with the diameter of phi 5-phi 6mm, the inert gas adopts helium gas for protection, the helium gas flow is 9-15L/min, the welding process is direct current welding, the welding speed range is 240 plus 300mm/min, and the welding current range is 180 plus 240A; the alternating current cover surface is also non-consumable electrode inert gas shielded welding, the non-consumable electrode uses a tungsten electrode with the diameter of phi 5-phi 6mm, the inert gas adopts argon gas for protection, the argon gas flow is 9-15L/min, the welding process is alternating current welding, the welding wire is automatically filled at the lower end of the tungsten electrode, the welding speed range is 120-160mm/min, the welding current range is 240-320A, and the wire feeding speed range is 600-1200 mm/min.
As an optional embodiment of the invention, taking the example that the welding thickness of the joint of the cylinder section and the flange is 7mm, the parameters of the direct current backing welding are selected as follows: the flow rate of the helium is 12-13L/min, the welding speed is 270mm/min, and the welding current is 185-195A; the selection of each parameter of the AC cover surface welding is as follows: the argon flow is 12-13L/min, the welding speed is 140mm/min, the welding current is 290-310A, and the wire feeding speed is 700-900 mm/min.
The direct current welding uses the electric arc of helium protection that has stronger penetrating power to weld, because flange 3 welding seam is confined annular welding seam, the shrink force of carrying out the welding part earlier can lead to symmetrical position clearance grow, leads to easily when welding to symmetrical position the defect of weld leakage anti-pumping. Aiming at the problem, before backing welding, a segmented positioning welding method is adopted to weld and fix the gaps and the staggered joints of the whole circle, so that the assembly effect of the whole circle is not changed during backing welding, and the backing welding quality is ensured. The segmented tack welding process comprises the steps that according to the clockwise direction, the uppermost end is 0 degree, the welding gun 10 rotates to two positions of 120 degrees and 240 degrees respectively, direct current welding is conducted, the welding process is the same as the backing welding mode, only the adopted current is small, the current range is 120 plus 180A, the thickness of a welding region is 7mm, the welding region is preferably 150A, welding leakage does not occur on the back of the involution position, only partial fusion is conducted on the involution position, the positioning effect is achieved, the welding length of each segment is about 40-50mm, and backing welding arcs from the 0 degree position, so that the involution gap and the staggered joint in the welding process are guaranteed to meet the welding requirements all the time. A schematic of the segmented tack weld is shown in fig. 6.
Generally, a closed annular welding seam needs to be welded for a circle without arc quenching, the welding is continued for a distance of 20-90 degrees, and the arc quenching is carried out after a section of welding seam which is not full in the arc starting stage is covered. Because the lap joint part which is continuously welded is subjected to secondary welding, the heat input of a welding seam is inevitably large, and the welding deformation is large. Although the overlapping amount cannot be avoided, the overlapping section of the backing welding and the overlapping section of the cover surface welding can be symmetrically distributed, so that the welding deformation caused by heat input is partially offset at the symmetrical position, the distribution of the heat input is further effectively controlled, and the welding deformation is reduced. The schematic diagram of the symmetrically distributed overlapping amount is shown in fig. 7, the backing weld starts from 0 degrees, and after one circle of welding, the welding is overlapped to the range of 20 degrees to 90 degrees; the welding of the cover surface starts from 180 degrees, and after one circle of welding, the cover surface is overlapped to the range of 200 degrees to 270 degrees.
Although the welding heat input is effectively controlled and the deformation amount is controlled, the welding deformation still exists due to the existence of the welding residual stress. Aiming at the situation, a manual shape correction method is adopted to eliminate welding residual stress and restore the molded surface before deformation. The shaping process comprises heating the weld seam to be knocked by a hot air blower, measuring the surface temperature of the heated area by an infrared thermometer, and controlling the temperature at 60-100 ℃, preferably 80 ℃; then, manually extruding the deformed convex part on the periphery of the welding line by using a square block to reduce the convex degree by 50-100%, preferably 80%; then knocking the back of the heated welding seam by using a hammer, and manually supporting the welding seam on the front of the welding seam at the corresponding position by using a square jacking block; finally, a broach is used to scrape off the hardened layer on the front and back of the weld, which is produced by knocking and bumping. The whole process is as shown in fig. 8, the welding seam is knocked step by step in a whole circle by adopting the method until the deformed bulge at the periphery of the welding seam is recovered, and the difference value between the actual profile and the theoretical profile of the product can be controlled within 3 mm.
In summary, the invention analyzes the characteristics of the storage box structure, adjusts the order of opening, enables the cylinder section to be in a flat lying posture in a single cylinder section state, fixes and supports the cylinder section by using the internal supporting device, and mechanically opens the outside of the cylinder section, thereby ensuring the accuracy of opening, the accuracy when the opening part of the cylinder section is matched with the flange, and further ensuring the welding quality. Meanwhile, the cylinder section is hoisted to be in a vertical state under the state of a single cylinder section, the lower end of the cylinder section is placed on the bracket, the flange is assembled, a tool is used for compressing the welding end of the cylinder section and the flange, a welding gun is deeply inserted into the inner side of the cylinder section to complete the automatic welding work of the flange, and a method of sectional positioning and symmetrical distribution of lap joint amount is adopted in the welding process, so that the heat input amount of the whole circle of welding is uniformly distributed while the quality of a welding seam is ensured, and the deformation amount near the welding area is reduced. In addition, the product profile recovery effect is good by adopting a manual shape correction method of heating a welding seam area, extruding a deformation area and knocking the welding seam area.
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, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (10)
1. The assembling welding and form and position size control method of the 5-meter-diameter cylinder section flange is characterized by comprising the following steps of: comprising the steps of mechanically perforating and welding flanges to individual target barrel sections to be welded prior to forming the closed tank.
2. The assembly welding and form and position size control method of the 5-meter-diameter cylinder section flange as claimed in claim 1, wherein the method comprises the following steps: the method for mechanically drilling the hole on the single target cylinder section needing the welding flange comprises the following steps: placing the cylinder section on a platform in a lying posture, rounding the cylinder section by using an internal bracing device, and drilling holes at a specified position outside the cylinder section by using a milling cutter;
preferably, when the hole is opened, a method is adopted in which a hole smaller than the target hole diameter by a certain length range is opened at a specified position, and then the milling diameter is gradually enlarged outwards until the target opening diameter is reached.
3. The assembly welding and form and position size control method of the 5-meter-diameter cylinder section flange as claimed in claim 2, wherein the method comprises the following steps: the inner supporting device is a 5M-level storage box sealing circular seam inner supporting device;
and/or the standard of using the internal support device to support the cylinder section into a circle is to tightly support the inner side of the cylinder section and ensure that the roundness of the whole circle of the outer side of the cylinder section is within 0.2 mm.
4. The method for assembling, welding and controlling the form and position dimensions of the 5-meter-diameter cylinder section flange according to any one of claims 1 to 3, is characterized in that: the method for welding the flange comprises the following steps:
1) vertically hoisting the perforated cylinder section to a bracket, enabling the perforated position to face towards the right lower side, assembling a flange at the perforated position, and fixing the cylinder section and a flange welding area by using a tool;
2) after the direct current positioning welding is carried out by adopting the sectional positioning, the backing welding and the cover surface welding are carried out by adopting a mode of symmetrically distributing the lap joint quantity;
3) and releasing residual stress for the welding seam by adopting a knocking shape correction method, and recovering the molded surface of the product.
5. The assembly welding and form and position size control method of the 5-meter-diameter cylinder section flange as claimed in claim 4, wherein the method comprises the following steps: in the step 1), the cylinder section and the flange welding area are assembled in an interference fit mode, the joint is completely closed without a gap, and the gap is within 0.2 mm.
6. The assembly welding and form and position size control method of the 5-meter-diameter cylinder section flange as claimed in claim 4, wherein the method comprises the following steps: in the step 1), the tool for fixing the cylinder section and the flange welding area comprises a cylinder section pressing beam and a plurality of cylinder section pressing rods arranged on the cylinder section pressing beam, wherein the cylinder section pressing rods are distributed at intervals along one circle of the periphery of the flange welding area, and the tail ends of the cylinder section pressing rods are attached with cylinder section pressing discs; the cylinder section pressing disc is annular and is positioned at the periphery of the flange welding area, and the lower end of the cylinder section pressing disc is tightly attached to the inner surface of the cylinder section; the cylinder section pressing beam is detachably fixed on the bracket;
and/or, in the step 1), an annular suspension groove for forming welding leakage in the welding process is arranged on the bracket.
7. The assembly welding and form and position size control method of the 5-meter-diameter cylinder section flange as claimed in claim 4, wherein the method comprises the following steps: in the step 2), the method for performing direct current positioning welding by adopting segmented positioning comprises the following steps: and respectively rotating the welding gun to two positions of 120 degrees and 240 degrees, performing direct current positioning welding, wherein the welding length of each section is about 40-50mm, and positioning the whole circle of involution.
8. The assembly welding and form and position size control method of the 5-meter-diameter cylinder section flange as claimed in claim 4, wherein the method comprises the following steps: in the step 2), the method for performing backing welding and cover surface welding by adopting a mode of symmetrically distributing lap joint quantity comprises the following steps: the backing welding is started from 0 degree, and after one circle of welding, the welding is overlapped to the range of 20-90 degrees; the arc is started from 180 degrees in the cover surface welding process, and after one circle of welding, the cover surface is overlapped to the range of 200-270 degrees, so that the distribution of heat input is effectively controlled, and the welding deformation is reduced.
9. The assembly welding and form and position size control method of the 5-meter-diameter cylinder section flange as claimed in claim 4, wherein the method comprises the following steps: in the step 3), a method for releasing residual stress of the welding seam by adopting a knocking shape correction method comprises the following steps: heating the welding seam area, extruding the deformation convex area, supporting the front side of the welding seam, knocking the back of the welding seam, scraping a hardened layer of the welding seam, and knocking and correcting the shape of the whole circle step by step until the deformation convex area at the periphery of the welding seam is recovered;
preferably, the temperature of the heating weld zone is controlled to be 60-100 ℃.
10. The assembly welding and form and position size control method of the 5-meter-diameter cylinder section flange as claimed in claim 1, wherein the method comprises the following steps: the method of forming a closed tank comprises the steps of:
(1) the first box bottom and the first cylinder section are welded in a butt joint mode;
(2) the first cylinder section and the second cylinder section are welded in a butt joint mode, and the rest is done in the same way until all the cylinder sections are welded in a butt joint mode;
(3) and the other box bottom and the last cylinder section are welded in a matching way to form a closed storage box.
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| CN201911384329.1A CN111069856A (en) | 2019-12-28 | 2019-12-28 | Assembling welding and shape and position size control method for 5-meter-diameter cylinder section flange |
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Application publication date: 20200428 |