CN111250824A - Welding device and repair process for inner hole wear surface of upper cross beam of large hydraulic press - Google Patents
Welding device and repair process for inner hole wear surface of upper cross beam of large hydraulic press Download PDFInfo
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- CN111250824A CN111250824A CN202010235664.1A CN202010235664A CN111250824A CN 111250824 A CN111250824 A CN 111250824A CN 202010235664 A CN202010235664 A CN 202010235664A CN 111250824 A CN111250824 A CN 111250824A
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- 238000003466 welding Methods 0.000 title claims abstract description 200
- 230000008439 repair process Effects 0.000 title claims abstract description 34
- 238000010438 heat treatment Methods 0.000 claims abstract description 74
- 238000004519 manufacturing process Methods 0.000 claims abstract description 15
- 241001669679 Eleotris Species 0.000 claims abstract description 6
- 229910000831 Steel Inorganic materials 0.000 claims description 27
- 239000010959 steel Substances 0.000 claims description 27
- 239000010410 layer Substances 0.000 claims description 22
- 230000007547 defect Effects 0.000 claims description 19
- 238000000034 method Methods 0.000 claims description 19
- 230000008569 process Effects 0.000 claims description 14
- 230000005540 biological transmission Effects 0.000 claims description 9
- 238000003754 machining Methods 0.000 claims description 9
- 238000007689 inspection Methods 0.000 claims description 7
- 230000037452 priming Effects 0.000 claims description 6
- 239000002893 slag Substances 0.000 claims description 6
- 239000002344 surface layer Substances 0.000 claims description 6
- 238000009434 installation Methods 0.000 claims description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical group [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 3
- 229910052799 carbon Inorganic materials 0.000 claims description 3
- 230000004927 fusion Effects 0.000 claims description 3
- 239000002932 luster Substances 0.000 claims description 3
- 239000000463 material Substances 0.000 claims description 3
- 238000004140 cleaning Methods 0.000 claims description 2
- 238000005520 cutting process Methods 0.000 claims description 2
- 238000012423 maintenance Methods 0.000 abstract description 3
- 230000006872 improvement Effects 0.000 description 8
- 238000005096 rolling process Methods 0.000 description 8
- 238000004321 preservation Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000007778 shielded metal arc welding Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
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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
- B23K9/0026—Arc welding or cutting specially adapted for particular articles or work
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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
- B23K9/02—Seam welding; Backing means; Inserts
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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
- B23K9/235—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
- B23K9/32—Accessories
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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
- B23P6/00—Restoring or reconditioning objects
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Abstract
The invention discloses a welding device for an inner hole wear surface of an upper cross beam of a large hydraulic press, which is characterized by comprising a bottom plate, a supporting seat, a sleeper, a welding gun and a central annular heating device; the central annular heating device is arranged at the center of the upper surface of the bottom plate, the supporting seats are arranged on the left side and the right side of the upper surface of the bottom plate in parallel, and sleepers are respectively arranged on each supporting seat; the welding gun is arranged at the central annular heating device. The invention also discloses a repair process of the wear surface of the inner hole of the upper cross beam of the large hydraulic press. The invention has the advantages of low investment cost, convenient field operation and maintenance, short repair time, greatly reduced production stop time and production stop loss, and greatly reduced purchasing cost of the upper beam of the large hydraulic press, wherein the upper beam after welding repair completely meets the service cycle of the large hydraulic press.
Description
Technical Field
The invention belongs to the field of machinery, and particularly relates to a welding device and a repairing process for an inner hole wear surface of an upper cross beam of a large hydraulic press.
Background
The main working flow of the production of the large hydraulic press for rolling wheels and ring parts of the rail transport company for the horse steel is that 32MPa high-pressure water passes through power generated by various regulating valves to efficiently drive the connected equipment to run rhythmically, so that the connected equipment is arranged in a main cylinder on an inner hole of an upper beam of a main core large spare part, a movable plunger in the main cylinder is matched with high precision to perform programmed up-and-down motion, and a heated steel ingot is subjected to upsetting and punching through various forming dies, so that the key standardized first working procedure for producing finished wheels and ring parts is accurately achieved. The standard parts of various wheels and ring parts are produced by rolling the product of the first process by a ring rolling mill, hot printing, heat treatment, finished product processing and the like. The important production process method has wide application in the industrial field of wheel and ring production for a long time. The upper beam of the core spare part of the 30MN large hydraulic press is made of ZG 35; the weight was 35T. The wear of the upper and lower contact surfaces of the inner hole of the upper cross beam and the outer side of the main cylinder which are matched with each other at high precision is caused due to the fact that the high-strength full load is matched with the main cylinder and the movable plunger piston in the main cylinder to move up and down in a programmed mode for a long time, the size of the wear surface of the inner hole of the upper cross beam is increased, a certain gap is generated between the wear surface of the inner hole of the upper cross beam and the outer side of the main cylinder, and the unstable factor of the integral coordinated rolling production of the large hydraulic press is seriously caused, so that a rolled product is influenced, if a new 30MN large hydraulic press core spare part upper cross beam is replaced, the cost. In order to recover production as soon as possible, a simple repair device needs to be designed, and wear surface overlaying and heat treatment processes based on different base metals are formulated and perfected by using the welding repair device, so that the worn upper cross beam can be reused economically, safely and reliably.
At present, surfacing repair of various ZG35 spare parts is common and is described in many documents, but no document exists for welding repair of a ZG35 spare part of an upper cross beam of a large hydraulic press, and the main difficulty of welding repair of the upper cross beam of the large hydraulic press lies in that after welding processes such as heating, operation, heat preservation and the like of an inner hole wear surface part of an upper cross beam to be welded are completed, structural deformation of the upper cross beam of the whole large hydraulic press is ensured to be avoided, and other rolling assembly parts are not influenced to be matched with precision installation of the upper cross beam of the large hydraulic press, and various non-standard performances are generated in internal tissues. In addition, the upper cross beam of the large hydraulic press after surfacing meets the requirement that the mechanical processing meets the operation size, and the surface cannot have any welding defect to avoid the subsequent influence on the quality of the operation period.
Disclosure of Invention
Aiming at the problems that rolling products are influenced after spare parts of the upper cross beam of the large hydraulic press are worn in the background technology, if the spare parts are replaced, the preset manufacturing time is relatively long, the investment cost is high, the production stop and the loss are relatively large, the invention designs and manufactures a welding device and a repair process of the inner hole wear surface of the upper cross beam of the large hydraulic press by utilizing the existing resources and implements the welding device and the repair process, the investment cost is low, the field operation and maintenance are convenient, the repair time is short, the production stop time and the production stop loss are greatly reduced, the service cycle of the upper cross beam after welding and repairing completely meets the service cycle of the upper cross beam of the large hydraulic press, and the purchase cost of the upper cross beam of the large.
The technical scheme for solving the technical problem of the invention is as follows:
the invention relates to a welding device for an inner hole wear surface of an upper cross beam of a large hydraulic press, which is characterized by comprising a bottom plate, a supporting seat, a sleeper, a welding gun and a central annular heating device; the central annular heating device is arranged at the center of the upper surface of the bottom plate, the supporting seats are arranged on the left side and the right side of the upper surface of the bottom plate in parallel, and sleepers are respectively arranged on each supporting seat; the welding gun is arranged at the central annular heating device.
As a further improvement of the technical scheme of the invention, the central annular heating device comprises a cylindrical heater support arranged at the center of the bottom plate, a gas transmission pipeline and a plurality of nozzles; an upper annular heating pipe and a lower annular heating pipe are respectively arranged at the upper part and the lower part of the outer side of the heater support, and are communicated with the gas transmission pipeline; the plurality of nozzles are respectively and uniformly arranged on the outer sides of the upper annular heating pipe and the lower annular heating pipe.
As a further improvement of the technical scheme of the invention, the gas pipeline is characterized in that a pressure gauge is also arranged on the gas pipeline.
As a further improvement of the technical scheme of the invention, the bottom plate is a rectangular steel plate with the thickness of 50mm, and the supporting seat is H-shaped steel with the specification of 250 mm.
As a further improvement of the technical scheme of the invention, the upper annular heating pipe and the lower annular heating pipe are respectively and fixedly connected to the heater support through a plurality of connecting rods.
The other technical scheme for solving the technical problem of the invention is as follows:
the invention relates to a repair process of an inner hole wear surface of an upper beam of a large hydraulic press, wherein upright post holes are symmetrically arranged on the left side and the right side of the upper beam respectively, an inner hole is arranged at the center of the upright post holes, a plurality of inner hole upper and lower wear surfaces are respectively formed at the upper position and the lower position of the inner hole of the upper beam after the upper beam runs for a long time, the repair process is carried out by applying a welding device of the inner hole wear surface of the upper beam of the large hydraulic press in the technical scheme, and the repair process comprises the following steps:
step one, processing and setting the welding device; processing and manufacturing the welding device of the inner hole wear surface of the upper cross beam of the large hydraulic press according to the specification of the upper cross beam to be repaired, and placing the upper cross beam on the welding device;
step two, preparing before welding;
2.1), the welding equipment adopts a digital control inverse manual direct current welding machine, the welding rod adopts an E5015 welding rod, the temperature is kept constant after baking, and the welding rod can be taken at any time;
2.2) the defect back chipping equipment is a carbon arc air gouging matched with a plasma air gouging;
2.3), oil stains, oxide layers, moisture and the like cannot be generated in a welding position area and a welding rod, and the metallic luster needs to be exposed;
2.4), welding technical requirements: the overlaying layer fuses base materials, and a welding seam cannot have any welding defects;
2.5), the upper beam is made of ZG 35;
2.6) auxiliary facilities: the device comprises a heat-insulating barrel, a sample plate, a thermodetector, a magnifier, a mask, gloves, a slag removal hammer, a chisel, a file, a wire brush, abrasive paper, a steel ruler, a horizontal ruler, a movable spanner, a straight grinder, an angle grinder, a wire pliers, a steel saw blade, a labor protection article and the like;
2.7) determining welding process parameters according to the specification of the upper cross beam;
preheating upper and lower wear surfaces of an inner hole of the upper cross beam;
the upper and lower worn surfaces of the inner hole of the upper cross beam are subjected to vertical symmetrical segmented vertical welding surfacing, the upper and lower worn surfaces of the inner hole on the upper cross beam are respectively marked in a segmented symmetrical mode by a straight steel ruler and a horizontal ruler before welding, then the upper and lower worn surfaces of the inner hole are preheated by a central annular heating device on the installed welding device, the heating temperature of each nozzle is uniformly transferred from the outside to the inside, and the preheating temperature is set to be 80-150 ℃;
welding the upper and lower worn surfaces of the inner hole of the upper cross beam and carrying out postweld heat treatment;
4.1) after the upper and lower worn surfaces of the inner hole reach the preheating temperature set by the process, performing vertical welding and upward surfacing by using an E5015 welding rod with equal strength, firstly performing priming welding, performing linear strip-conveying rapid short-arc welding, wherein the welding line needs to meet the requirements of the combination of the welding bottom and a molten pool and the fusion between the upper and lower welding lines, cleaning the welding line by using a slag removal hammer and an angle grinder after the priming welding, detecting whether the welding line has welding defects by using a magnifying lens of 10 times, and immediately performing root-removing welding repair by using a plasma gas planing cutting machine once the welding defects such as cracks, air holes and the like are found;
4.2) after the bottoming layer is determined to be free of defects, starting the welding gun to weld two or more filling layers and a cover surface layer by using an E5015 welding rod with equal strength, performing surfacing by using a short arc of a regular triangle strip conveying method or a medium arc length of 5-8 mm, covering the welding seam of the cover surface layer with the width of the welding seam of the surfacing layer and the upper beam body so as to ensure the required size of subsequent machining, performing omnibearing welding inspection, and removing the welding gun after directly observing or using a magnifying lens with the power of 10 times to find out the welding is qualified and no welding defects are determined;
4.3), starting the central annular heating device again to continue heating the upper and lower worn surfaces of the inner hole of the upper cross beam of the large hydraulic press to 450-550 ℃, and keeping the temperature for 10 hours to slowly cool the upper and lower worn surfaces until the temperature is cooled to room temperature;
4.4) finally machining the upper and lower worn surfaces of the inner hole of the upper cross beam of the large hydraulic press after welding repair on site by using a machine tool until the upper and lower worn surfaces meet the assembly size, and delivering for use after acceptance inspection and installation requirements are met.
As a further improvement of the technical scheme of the invention, when the welding device for the inner hole wear surface of the upper beam of the large hydraulic press is processed and manufactured according to the specification of the upper beam to be repaired, a rectangular steel plate with the area larger than 50mm of the bottom surface of the upper beam is cut as a bottom plate, one surface of the rectangular steel plate is horizontally placed on the ground, the other surface of the rectangular steel plate is horizontally and symmetrically welded and connected with two H-shaped steels with the specification of 250mm as a supporting seat according to the positions of four upright post holes on the left side and the right side of the upper beam on the bottom plate, sleepers are fixedly placed on the grooves of the supporting seat, then the upper beam is placed on the sleepers, the stable horizontal placement of the upper beam of the whole large hydraulic press under the condition of meeting the height is ensured firstly, then the contact surfaces of the bottom surfaces of the four upright post holes of the upper beam are placed through the sleepers are not damaged, then a central, The welding rod at the welding position of the lower wear surface and the overlaying surface can form an included angle of 70-85 degrees.
As a further improvement of the technical scheme of the invention, an E5015 welding rod adopted by the repair process is baked for 2 hours at 300-350 ℃, and then is kept at a constant temperature and taken at any time.
As a further improvement of the technical scheme of the invention, a central annular heating device is used for preheating the upper and lower worn surfaces of the inner hole to 80-150 ℃ before welding, so that the preheating temperature is ensured to rise uniformly at 20 ℃/h; after welding repair, the central annular heating device is used for heating the upper and lower worn surfaces of the inner hole to 450-550 ℃, and the heating temperature is ensured to rise uniformly at 100 ℃/h.
As a further improvement of the technical scheme of the invention, the bottom layer adopts an E5015 welding rod with the diameter of 4.0mm, the welding current is 120-160A, the arc voltage is 22 +/-1V, the welding speed is 15 +/-1 cm/min, the filling layer and the cover layer adopt the E5015 welding rod with the diameter of 5.0mm, the welding current is 140-180A, the arc voltage is 25 +/-1V, and the welding speed is 17 +/-1 cm/min.
Compared with the prior art, the welding device for the inner hole wear surface of the upper beam of the large hydraulic press has the advantages of simple, novel and practical structure, safe and easy operation, stable welding quality, low investment cost, high working efficiency, capability of meeting the actual field requirements, great reduction of maintenance cost, reduction of shutdown loss caused by abrasion and replacement of the upper beam, and guarantee for assembly of wheels and ring members with various specifications.
Drawings
The invention is further described with reference to the following figures and detailed description:
FIG. 1 is a schematic structural diagram of a welding device for an inner hole wear surface of an upper cross beam of a large hydraulic press according to the present invention;
FIG. 2 is a schematic view of a top view of a welding device for an inner hole wear surface of an upper cross beam of a large hydraulic press according to the present invention;
FIG. 3 is a schematic structural view of an upper cross beam of the hydraulic press according to the present invention;
FIG. 4 is a schematic top view of the upper cross member of the hydraulic press of the present invention;
in the figure: 1. the bottom plate 2, the supporting seat 3, the sleeper 4, the upper cross beam 5, the heater support 6, the inner hole upper wear surface 7, the inner hole lower wear surface 8, the upper annular heating pipe 9, the nozzle 10, the pressure gauge 11, the gas transmission pipeline 12, the welding gun 13, the connecting rod 14, the stand column hole 15, the central annular heating device 16, the lower annular heating pipe 17 and the inner hole.
Detailed Description
Example 1:
as shown in fig. 1 to 4, the welding device for the inner hole wear surface of the upper beam of the large hydraulic press is characterized by comprising a bottom plate 1, a supporting seat 2, a sleeper 3, a welding gun 12 and a central annular heating device 15; the bottom plate 1 is a rectangular steel plate with the thickness of 50mm, the center of the upper surface of the bottom plate is provided with the central annular heating device 15, the left side and the right side of the upper surface of the bottom plate are provided with the supporting seats 2 in parallel, each supporting seat 2 is provided with a sleeper 3, and the supporting seats 2 can be made of H-shaped steel with the specification of 250 mm; the welding torch 12 is arranged at a central annular heating device 15.
In this embodiment, the central annular heating device 15 includes a cylindrical heater support 5 disposed at the center of the bottom plate 1, a gas transmission pipeline 11 and a plurality of nozzles 9; an upper annular heating pipe 8 and a lower annular heating pipe 16 are respectively arranged at the upper part and the lower part of the outer side of the heater support 5, and the upper annular heating pipe 8 and the lower annular heating pipe 16 are both communicated with the gas transmission pipeline 11; the nozzles 9 are respectively and uniformly arranged on the outer sides of the upper annular heating pipe 8 and the lower annular heating pipe 16 so as to uniformly heat the wear surface of the inner hole of the upper cross beam.
In this embodiment, the gas transmission pipeline 11 is further provided with a pressure gauge 10, a control valve and other components.
In this embodiment, in order to facilitate the arrangement of the upper annular heating pipe 8 and the lower annular heating pipe 16 on the heater support, the upper annular heating pipe 8 and the lower annular heating pipe 16 are respectively and fixedly connected to the heater support 5 through a plurality of connecting rods.
Example 2:
as shown in fig. 1 to 4, the repair process for the wear surface of the inner hole of the upper beam of the large hydraulic press according to the present invention includes the following steps:
step one, processing and manufacturing a welding device of the inner hole wear surface of the upper cross beam of the large hydraulic press; the welding device for the inner hole wear surface of the upper cross beam of the large hydraulic press, which is described in embodiment 1, is processed and manufactured according to the specification of the upper cross beam 4 to be repaired, and after the welding device is manufactured, the upper cross beam 4 is placed on the welding device; when the welding device is manufactured, a 50mm thick rectangular steel plate with the area larger than the bottom surface of an upper beam 4 is firstly cut to serve as a bottom plate 1, one surface of the steel plate is horizontally placed on the ground, the other surface of the steel plate is horizontally and symmetrically welded with two H-shaped steels with the specification of 250mm serving as a supporting seat 2 on the bottom plate 1 according to the positions of four left and right upright post holes 14 of the upper beam 4, sleepers 3 are fixedly placed on grooves of the supporting seat 2, then the upper beam 4 is rotated on the two sleepers 3, firstly the stable horizontal placement of the upper beam 4 of the whole large hydraulic press under the condition of meeting the height is ensured, secondly the contact surfaces of the bottom surfaces of the four upright post holes 14 of the upper beam 4 are placed through the sleepers 3 and are not damaged, and parts of a central annular heating device 15 are further installed, wherein a heater support 5 is placed in the middle position of an inner hole 17 of, The middle positions of the lower wear surfaces 6 and 7 are placed and fixedly welded on a heater support 5 by adopting a plurality of connecting rods 13, then a plurality of nozzles 9 are uniformly arranged on the upper and lower annular heating pipes 8 and 16, a pressure gauge 10 is arranged on a conveying gas pipe 11, and an air source is communicated, so that the welding device has the processes of preheating, heating and heat preservation of the upper and lower wear surfaces 6 and 7 of the inner hole before welding repair, and finally a welding gun 12 is arranged and the welding rod at the welding position of the welding gun 12 on the upper and lower wear surfaces 6 and 7 of the inner hole and the overlaying surface can form an included angle of 70-85 degrees;
step two, preparing before welding;
2.1, adopting HT400D digital control inversion type manual direct current welding machine as welding equipment, wherein a welding gun 12 is a 600A welding rod, and E5015 welding rods with the diameters of phi 4.0mm and phi 5.0mm, which are adopted by the welding rods, are baked for 2 hours at 300-350 ℃ and then are kept at constant temperature for use and taking at any time;
2.2, the defect back chipping equipment is a carbon arc air gouging ZX5-630 welding machine matched with a plasma air gouging LGK-100 MA;
2.3, oil stains, oxide layers, moisture and the like cannot be generated in the welding position area and the welding rod, and the metallic luster needs to be exposed;
2.4, welding technical requirements: the overlaying layer fuses base materials, and a welding seam cannot have any welding defects;
2.5, the upper beam 4 is made of ZG 35;
2.6 auxiliary facilities: the device comprises a heat-insulating barrel, a sample plate, a thermodetector, a magnifier, a mask, gloves, a slag removal hammer, a chisel, a file, a wire brush, abrasive paper, a steel ruler, a horizontal ruler, a movable spanner, a straight grinder, an angle grinder, a wire pliers, a steel saw blade, a labor protection article and the like;
2.7, determining welding process parameters according to the specification of the upper cross beam 4;
manual shielded metal arc welding
Preheating upper and lower wear surfaces 6 and 7 of an inner hole of the upper cross beam 4;
because the upper and lower worn surfaces 6 and 7 of the inner hole of the upper beam 4 of the large hydraulic press are larger, considering that the deformation of the integral upper beam structural part is generated if large-area overlaying is carried out, and the scrapping of the upper beam of the large hydraulic press is directly caused, in order to ensure repair welding and meet the use process requirements for a long time and not scrap the integral upper beam, an up-down symmetrical segmented vertical welding overlaying mode is adopted on the upper and lower worn surfaces 6 and 7 of the inner hole of the upper beam 4 of the large hydraulic press, so that the subsequent machining size of the inner hole worn surface of the upper beam is met and the deformation of the integral structural part is prevented, the upper and lower worn surfaces 6 and 7 of each inner hole on the upper beam 4 are respectively marked by a steel ruler and a horizontal ruler in a segmented symmetrical mode before welding, then a central annular heating device 15 on the welding device is used for integrally preheating the upper and lower worn surfaces 6 and 7 of the inner hole, the temperature heated by each nozzle 9 is uniformly transferred from the outside, the preheating temperature is set to be 80-150 ℃, and during preheating, the preheating temperature is ensured to rise uniformly at 20 ℃/h, so that the micro-cracks are generated inside the upper and lower worn surfaces 6 and 7 of the inner hole of the integral upper cross beam 4 of the large hydraulic press due to non-uniform high-temperature heating, and the heating of the integral upper cross beam of the large hydraulic press can reduce the local temperature difference stress, improve the internal structure and prevent or reduce the hardening structure;
welding and post-welding heat treatment of the upper and lower wear surfaces 6 and 7 of the inner hole of the upper cross beam 4; 4.1, after the upper and lower worn surfaces 6 and 7 of the inner hole reach the preheating temperature set by the process, adopting an E5015 welding rod with equal strength to vertically weld and upwards build up weld, firstly performing priming welding, adopting the welding rod with the diameter of 4.0mm, adopting the vertical welding and upwards build up weld completely, and adopting a slightly smaller current to linearly transport the strip for quick short-arc welding, wherein the welding line is not too wide but needs to meet the combination of the bottom of the weld and a molten pool and the fusion between the upper welding line and the lower welding line, the welding line is cleaned by a slag removal hammer and an angle grinder after the priming welding, then a magnifier of 10 times is used for checking whether the welding line has welding defects, once the welding defects such as cracks, air holes and the like are found, a plasma gas planing cutter is immediately used for back gouging repair welding, and the interlayer temperature must be ensured no matter of secondary repair welding or welding of a subsequent filling layer;
4.2, after the bottoming layer is determined to be free of defects, starting a welding gun to weld two or more filling layers and a cover surface layer by using an E5015 welding rod with equal strength, surfacing by using a welding rod with the diameter of 5.0mm and a short arc of a regular triangle strip conveying method or a medium arc length of 5-8 mm, covering the welding seam of the cover surface layer with the width (10-25 mm) of the welding seam of the surfacing layer and the upper beam body to ensure that the required size for subsequent machining has enough thickness, performing omnibearing welding inspection, and removing the welding gun 12 after directly observing or finding the welding seam with a magnifying glass of 10 times to be qualified and determining that no welding defect exists;
4.3, starting the central annular heating device again to continuously heat the upper and lower worn surfaces 6 and 7 of the inner hole of the upper cross beam 4 of the large hydraulic press to 450-550 ℃, ensuring that the heating temperature uniformly rises at 100 ℃/h during heating, keeping the temperature for 10 hours, slowly cooling until the temperature is cooled to room temperature, keeping the temperature for 10 hours to reduce the hardening degree, avoid embrittlement, eliminate welding stress and reach the process temperature required by welding;
4.4, finally, machining the upper and lower wear surfaces 6 and 7 of the inner hole of the welded and repaired upper cross beam 4 of the large hydraulic press on site by using a machine tool until the upper and lower wear surfaces meet the assembly size, and completely meeting the requirements of the inner hole of the upper cross beam of the integral large hydraulic press and the installation of other rolling assemblies and the upper cross beam through the inspection and acceptance of an on-site actual sample plate, delivering for use, and achieving the using effect of mechanical performance through the rolling operation inspection of periodic wheels and ring pieces.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are also included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope defined by the claims.
Claims (10)
1. A welding device for an inner hole wear surface of an upper cross beam of a large hydraulic press is characterized by comprising a bottom plate (1), a supporting seat (2), a sleeper (3), a welding gun (12) and a central annular heating device (15); the central annular heating device (15) is arranged in the center of the upper surface of the bottom plate (1), the supporting seats (2) are arranged on the left side and the right side of the upper surface in parallel, and sleepers (3) are respectively arranged on each supporting seat (2); the welding torch (12) is arranged at a central annular heating device (15).
2. The welding device for the inner hole wear surface of the upper cross beam of the large hydraulic press as recited in claim 1, wherein the central annular heating device (15) comprises a cylindrical heater support (5) arranged at the center of the bottom plate (1), a gas transmission pipeline (11) and a plurality of nozzles (9); an upper annular heating pipe (8) and a lower annular heating pipe (16) are respectively arranged on the upper and lower parts of the outer side of the heater support (5), and the upper annular heating pipe (8) and the lower annular heating pipe (16) are communicated with the gas transmission pipeline (11); the plurality of nozzles (9) are respectively and uniformly arranged on the outer sides of the upper annular heating pipe (8) and the lower annular heating pipe (16).
3. The welding device for the inner hole wear surface of the upper cross beam of the large hydraulic press as recited in claim 2, wherein a pressure gauge (10) is further arranged on the gas transmission pipeline (11).
4. The welding device for the inner hole wear surface of the upper cross beam of the large hydraulic press as recited in claim 2, wherein the upper annular heating pipe (8) and the lower annular heating pipe (16) are fixedly connected to the heater support (5) through a plurality of connecting rods (13), respectively.
5. The welding device for the inner hole wear surface of the upper cross beam of the large hydraulic press as claimed in any one of claims 1-3, wherein the bottom plate (1) is a rectangular steel plate with the thickness of 50mm, and the supporting seat (2) is H-shaped steel with the specification of 250 mm.
6. A repair process for inner hole wear surfaces of an upper beam of a large hydraulic press is characterized in that the repair process comprises the following steps:
step one, processing and setting the welding device; machining and manufacturing a welding device of the inner hole wear surface of the upper cross beam of the large hydraulic press according to the specification of the upper cross beam (4) to be repaired, wherein the welding device is used for machining and manufacturing the inner hole wear surface of the upper cross beam of the large hydraulic press according to the claims 1-5, and placing the upper cross beam (4) on the welding device;
step two, preparing before welding;
2.1), the welding equipment adopts a digital control inverse manual direct current welding machine, the welding rod adopts an E5015 welding rod, the temperature is kept constant after baking, and the welding rod can be taken at any time;
2.2) the defect back chipping equipment is a carbon arc air gouging matched with a plasma air gouging;
2.3), oil stains, oxide layers, moisture and the like cannot be generated in a welding position area and a welding rod, and the metallic luster needs to be exposed;
2.4), welding technical requirements: the overlaying layer fuses base materials, and a welding seam cannot have any welding defects;
2.5) and the upper beam (4) is made of ZG 35;
2.6) auxiliary facilities: the device comprises a heat-insulating barrel, a sample plate, a thermodetector, a magnifier, a mask, gloves, a slag removal hammer, a chisel, a file, a wire brush, abrasive paper, a steel ruler, a horizontal ruler, a movable spanner, a straight grinder, an angle grinder, a wire pliers, a steel saw blade, a labor protection article and the like;
2.7) determining welding process parameters according to the specification of the upper cross beam (4);
step three, preheating upper and lower wearing surfaces (6, 7) of an inner hole of the upper cross beam (4);
the upper and lower worn surfaces (6 and 7) of the inner hole of the upper cross beam (4) are subjected to vertical symmetrical segmented vertical welding surfacing welding, the upper and lower worn surfaces (6 and 7) of the inner hole on the upper cross beam (4) are respectively marked by a straight steel ruler and a horizontal ruler in a segmented symmetrical mode before welding, then the upper and lower worn surfaces (6 and 7) of the inner hole are preheated by a central annular heating device (15) arranged on the welding device, the heating temperature of each nozzle (9) is uniform and is transferred from the outside to the inside, and the preheating temperature is set to be 80-150 ℃;
welding and postweld heat treatment of upper and lower worn surfaces (6, 7) of an inner hole of the upper cross beam (4);
4.1) after the upper and lower worn surfaces (6, 7) of the inner hole reach the preheating temperature set by the process, performing vertical surfacing by using an E5015 welding rod with equal strength, firstly performing priming welding, performing linear strip conveying and rapid short-arc welding, wherein the welding seam needs to meet the combination of the welding bottom and a molten pool and the fusion between the upper and lower welding seams, cleaning the welding seam by using a slag removing hammer and an angle grinder after the priming welding, detecting whether the welding seam has welding defects by using a magnifying lens of 10 times, and immediately performing back-gouging weld repair by using a plasma gas gouging cutting machine once the welding defects such as cracks, air holes and the like are found;
4.2) after the bottoming layer is determined to be free of defects, starting a welding gun to weld two or more filling layers and a cover surface layer by using an E5015 welding rod with equal strength, surfacing by using a short arc of a regular triangle strip conveying method or a medium arc length of 5-8 mm, covering the welding seam of the cover surface layer with the width of the welding seam of the surfacing layer and the upper beam body so as to ensure the required size of subsequent machining, performing omnibearing welding inspection, directly observing or finding out the welding seam with a magnifying lens of 10 times, and removing the welding gun (12) after determining that no welding defect exists;
4.3) starting the central annular heating device again to continue heating the upper and lower worn surfaces (6, 7) of the inner hole of the upper cross beam (4) of the large hydraulic press to 450-550 ℃, and keeping the temperature for 10 hours to slowly cool the upper and lower worn surfaces until the temperature is cooled to room temperature;
4.4) and finally machining the upper and lower worn surfaces (6, 7) of the inner hole of the upper cross beam (4) of the large hydraulic press after welding repair on site by using a machine tool until the upper and lower worn surfaces meet the assembly size, and delivering for use after acceptance inspection and installation requirements are met.
7. The repairing process of the inner hole wear surface of the upper beam of the large hydraulic press as claimed in claim 6 is characterized in that when the welding device of the inner hole wear surface of the upper beam of the large hydraulic press as claimed in claims 1 to 5 is manufactured according to the specification of the upper beam (4) to be repaired, a rectangular steel plate with the area larger than 50mm of the bottom surface of the upper beam (4) is cut as a bottom plate (1), one side is horizontally placed on the ground, the other side is horizontally and symmetrically welded and connected with two H-shaped steels with the specification of 250mm as a supporting seat (2) according to the positions of four left and right upright post holes (14) of the upper beam (4), sleepers (3) are fixedly placed on grooves of the supporting seat (2), then the upper beam (4) is placed on the sleepers (3), and the upper beam (4) of the whole large hydraulic press is firstly ensured to be stably and horizontally placed under the condition of meeting the height, secondly, the contact surfaces of the bottom surfaces of four upright post holes (14) of the upper cross beam (4) are placed through the sleepers (3) and are not damaged, then a central annular heating device (15) is installed at an inner hole (17) of the upper cross beam (4), and finally a welding gun (12) is arranged and the welding rods of the welding gun (12) at the welding positions of the upper and lower worn surfaces (6 and 7) of the inner hole and a surfacing surface can form an included angle of 70-85 degrees.
8. The repair process of the inner hole wear surface of the upper cross beam of the large hydraulic press as claimed in claim 6, wherein an E5015 welding rod adopted in the repair process is baked at 300-350 ℃ for 2 hours, then is kept at a constant temperature, and is taken at any time.
9. The repair process of the inner bore wear surface of the upper beam of the large hydraulic press as claimed in claim 6, wherein the preheating temperature is ensured to rise uniformly at 20 ℃/h when the upper and lower wear surfaces (6, 7) of the inner bore are preheated to 80-150 ℃ by the central annular heating device (15) before welding; after welding repair, the central annular heating device (15) is used for heating the upper and lower worn surfaces (6, 7) of the inner hole to 450-550 ℃, and the heating temperature is ensured to rise uniformly at 100 ℃/h.
10. The repair process of the wear surface of the inner hole of the upper beam of the large hydraulic press as claimed in claim 6, wherein the bottom layer is made of E5015 welding rod with the diameter of 4.0mm, the welding current is 120-160A, the arc voltage is 22 +/-1V, the welding speed is 15 +/-1 cm/min, the filling layer and the cover layer are made of E5015 welding rod with the diameter of 5.0mm, the welding current is 140-180A, the arc voltage is 25 +/-1V, and the welding speed is 17 +/-1 cm/min.
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