CN112388106A - Multilayer multi-pass welding bead design method - Google Patents
Multilayer multi-pass welding bead design method Download PDFInfo
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- CN112388106A CN112388106A CN202011160590.6A CN202011160590A CN112388106A CN 112388106 A CN112388106 A CN 112388106A CN 202011160590 A CN202011160590 A CN 202011160590A CN 112388106 A CN112388106 A CN 112388106A
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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
- B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
- B23K9/133—Means for feeding electrodes, e.g. drums, rolls, motors
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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
Abstract
The invention relates to a design method of a multilayer multi-pass welding bead, which comprises the following steps of obtaining the total filling sectional areaSWhen the maximum allowable value of the residual height is obtained according to the size of the welding groove, the total filling sectional area of the welding wireS(ii) a Obtaining the sectional area occupied by the single welding seamS 1According to the diameter of the wiredWire feeding speedδAnd welding speedυObtaining the occupied sectional area of the single welding seamS 1(ii) a Obtaining the total number of welding beadsnAccording to the total filling cross-sectional areaSAnd the area of the single weldS 1Obtaining the total number of welding beadsn(ii) a According to the total number of welding beadsnAnd designing a welding bead. The method can correlate the welding parameters, the groove parameters and the weld bead arrangement through parametric calculation for welding process design, realize accurate planning of multilayer and multichannel welding beads and quantitative prediction of the weld beads, and further realize the accurate planning of the multilayer and multichannel welding beads and the quantitative prediction of the weld beadsAnd the fine management of the welding production process is realized, and the consistency of the product quality is improved.
Description
Technical Field
The invention relates to a design method of a multilayer multi-pass welding bead, and belongs to the technical field of welding.
Background
With the continuous aggravation of contradictions among environment, resources and social development, green manufacturing gradually becomes global consensus; the progress of the times and the innovation of the production technology promote the development direction of the new generation manufacturing industry, namely intelligent manufacturing. The green manufacturing becomes one of the development trends of the manufacturing industry, and meanwhile, the intelligent manufacturing is taken as the main attack direction of the transformation and upgrading of the manufacturing industry in China. The machinery manufacturing industry is not only a large household for energy resource consumption, but also an important source for environmental pollution, the development of green manufacturing becomes a great trend, simply speaking, resources are saved, and pollution is reduced; with the deep development of new generation technologies such as big data, internet of things, artificial intelligence, cloud computing and the like, intelligent manufacturing becomes a key measure for creating new kinetic energy and improving enterprise competitiveness, and system application of new technologies such as virtual manufacturing, simulation prediction, intelligent factories and the like can greatly shorten the development period and reduce the development cost.
In the process of welding process design, the traditional joint detail design only comprises groove characteristic parameters, a welding method and recommended welding parameters, no specific requirements are made on weld bead filling details in a groove, the operation is carried out by the experience of operators, and the instability of welding product quality is caused to a certain extent by the fuzzy operation.
Disclosure of Invention
The invention provides a parameterized multilayer multi-pass welding bead design method for improving the stability of the quality of a welding product, and the method can correlate welding parameters, groove parameters and welding bead arrangement through parameterized calculation and is used for welding process design, so that quantitative prediction of multilayer multi-pass welding beads is realized, further fine management of a welding production process is realized, and the consistency of the product quality is improved.
The technical scheme adopted by the invention is as follows: a design method of a multilayer multi-pass welding bead comprises the following steps of obtaining a total filling sectional area S, and obtaining the maximum allowable value of surplus height according to the size of a welding groove, wherein the total filling sectional area S of a welding wire is obtained;
obtaining the sectional area S occupied by the single welding seam1Obtaining the sectional area S occupied by the single welding line according to the diameter d of the welding wire, the wire feeding speed delta and the welding speed upsilon1；
Obtaining the total number n of welding beads, and occupying the welding beads of a single pass according to the total filling sectional area SCross sectional area S1Obtaining the total number n of welding beads;
and designing a welding bead according to the total number n of the welding beads.
Further, the welding groove is a V-shaped groove, and the size of the welding groove comprises a groove angle theta, a truncated edge e and a gap width a; the method for calculating the total filling sectional area S of the welding wire comprises the following steps:
a obtaining weld fusion width b
In the formula: a is the gap width, t is the workpiece thickness, e is the truncated edge, and theta is the bevel angle;
b obtaining the total filling sectional area S of the welding wire
In the formula: lambda is an equivalent coefficient, b is weld fusion width, h is weld reinforcement height, a is gap width, t is workpiece thickness, e is a truncated edge, and theta is a groove angle;
when the welding groove is a V-shaped groove, designing welding beads according to the total number n of the welding beads as follows: the number of welding beads increases gradually from the bottoming layer to the top layer, wherein the bottoming layer is the welding bead arranged in the lowest layer in the welding seam.
Furthermore, the weld reinforcement h satisfies h is less than or equal to 1+0.1b, and h is not more than 5 mm.
Further, the wire feeding speed δ is obtained by the following formula
δ＝k1I+k2
In the formula: k is a radical of1Is a linear proportionality coefficient, k2Is constant, I is the welding current.
Further, the occupied area S of the single welding seam1Is calculated by
In the formula: d is the diameter of the welding wire, delta is the wire feeding speed, and upsilon is the welding speed.
Furthermore, the welding interface is one of a V-shaped, a U-shaped, an X-shaped, a single-side V-shaped and a K-shaped.
Further, the total number of passes n is obtained by the following formula
Wherein eta is a welding wire loss correction coefficient, S is a total filling sectional area, S1The area of the single welding line is the sectional area occupied by the single welding line.
Further, the quality M of the welding wire required by the welding seam is obtained,
in the formula, rho is welding wire density, d is welding wire diameter, delta is wire feeding speed, upsilon is welding speed, and L is0Is the weld length.
Further, the maximum allowable value of the residual height is the maximum allowable value of the residual height meeting the quality requirement of the welding seam in grade B in ISO 5817.
The beneficial effects produced by the invention comprise:
the invention establishes a mathematical relation model among welding parameters, welding wire specification parameters and groove characteristic parameters, can accurately predict the number of welding beads in advance at a design end and carry out planning and arrangement, reduces the influence of human factors on the welding seam forming and quality, improves the consistency of the welding quality of products, and also effectively improves the working efficiency of welding process personnel and the control force on the welding quality. Meanwhile, parameterization and modeling of the whole welding process flow lay a strong foundation for standardization and intellectualization of subsequent welding process design and production, and the international market competitiveness of enterprises in the welding manufacturing industry is remarkably enhanced.
Drawings
FIG. 1 is a schematic diagram of a V-groove weld cross-section structure and related characteristic parameters;
FIG. 2 is a schematic cross-sectional view of a weld bead after the weld bead has completely filled the groove;
in the figure, 1, a workpiece, 2, a groove, 3 and a weld bead.
Detailed Description
The present invention is explained in further detail below with reference to the drawings and the specific embodiments, but it should be understood that the scope of the present invention is not limited to the specific embodiments.
A design method of a parameterized multilayer multi-pass welding bead 3 comprises the following steps (taking a V-shaped groove 2 as an example):
(1) obtaining the thickness t and the length L of a welding seam of a workpiece 10The shape and size of the V-shaped groove 2 (including the angle theta of the groove 2, the truncated edge e and the gap a) are shown in figure 1;
(2) according to the relative sizes of the groove 2, such as the thickness t of the workpiece 1, the angle theta of the groove 2, the truncated edge e, the gap a and the like, when the maximum allowable value of the residual height meeting the B-grade quality requirement of a welding seam in ISO 5817 is obtained through geometric calculation, the total filling sectional area S is obtained;
(3) calculating to obtain the sectional area S of the single welding line through the diameter d (such as 1.2mm), the wire feeding speed delta and the welding speed upsilon1；
(4) Through the total filling sectional area S and the sectional area S occupied by the single welding seam1Obtaining the total number n of the welding beads 3 required by the final welding bead formed after the welding beads 3 are filled;
(5) planning the distribution and sequence of welding tracks according to the habit of adapting to manual welding operation, as shown in fig. 2;
the welding bead distribution adopts layer-by-layer upward accumulation: in the multilayer and multi-pass welding, in order to realize complete penetration of the back surface, the parameters of the bottoming layer are obviously different from those of the later layer, so that the area of the welding bead of the layer is also different from that of other welding beads, and the number and distribution of the welding beads are finally determined (stacked layer by layer and upwards) according to the actually planned test parameters;
the welding sequence adopts from bottom to top, from right to left: according to the manual welding operation habit, the operator welds facing the weld, thus presenting the stacking effect shown in the figure (bottom-up, right-to-left). Correspondingly, the welding sequence can be changed at will by adjusting the posture of the welding gun in the robot welding process.
(6) According to the welding adaptation characteristics of the related welding machine, a mathematical relation model between the wire feeding speed and the welding current is obtained, and meanwhile, the welding wire quality M required by the whole welding seam after the completion of filling can be obtained.
In the step (1), the thickness of the workpiece refers to the thickness of the part, close to the parent metal at two sides of the groove, namely the thickness of the parent metal at two sides of the groove; the length of the weld seam is the total length of the continuous extension of the groove shape and is usually the total length between the starting point and the arc point in the case of continuous welding.
In the step (2), "ISO 5817 welding-melting welding joint of steel, nickel, titanium and alloy thereof: the default quality grade provides that the B-level welding seam residual height h is less than or equal to 1+0.1B, the maximum h is not more than 5mm, and B is the welding seam melt width (equivalent to the width of a groove opening when participating in calculation) and can be obtained by the formula (2-1);
in the formula: a is the gap width, t is the workpiece thickness, e is the truncated edge, and theta is the bevel angle;
the formula for obtaining the total filling sectional area is shown as a formula (2-2), wherein lambda is an equivalent coefficient.
In the formula: lambda is equivalent coefficient, b is weld fusion width, h is weld residual height, a is gap width, t is workpiece thickness, e is truncated edge, and theta is groove angle.
In the step (3), the formula for obtaining the sectional area occupied by the single welding seam is shown as the formula (2-3).
In the formula: d is the diameter of the welding wire, delta is the wire feeding speed, and upsilon is the welding speed.
Wherein, the wire feeding speed is obtained by a mathematical relation model with the welding current, as shown in the formula (2-4). k is a radical of1、k2Linear proportionality coefficients and constants, respectively.
δ＝k1I+k2 (2-4)
In the step (4), a formula for obtaining the total number of welding passes is shown as a formula (2-5), wherein eta is a welding wire loss correction coefficient.
In the step (5), the operation method of the weld bead planning is to start welding the weld bead of each weld layer from the same side of the groove until the weld layer is full, and in general, the number of the weld beads is increased gradually from the bottom layer to the top layer by layer (the welding mode and parameters of the weld bead outside the bottom layer need to be kept consistent), as shown in fig. 2, the large opening end of the V-shaped groove is taken as the top, and the narrow opening end is taken as the bottom.
In the step (6), the total mass of the welding wires required for completing the whole welding seam is shown as the formula (2-6), and rho is the density of the welding wires.
In the formula, rho is welding wire density, d is welding wire diameter, delta is wire feeding speed, upsilon is welding speed, and L is0Is the weld length.
The calculation of the welding wire quality can predict the welding wire usage before welding, which is beneficial to the management of the welding material usage; and secondly, the predicted welding wire amount in advance can be verified and compared with the actual welding wire amount after welding, so that the subsequent further optimization and correction of welding process parameters are facilitated, and the welding quality is improved.
The parameterization principle of the scheme is that only a welding process procedure (WPS) output from a welding process design end obtains a proper welding current I, the wire feeding speed delta can be obtained by automatic matching calculation aiming at a corresponding welding machine, the number n of welding beads required for filling a groove to form a complete welding seam is automatically calculated by combining groove characteristic parameters, and then the distribution of the welding beads is planned, layered and arranged. Therefore, the welding wire consumption can be predicted in advance, the control residual height is ensured on the premise of full welding, and the appearance quality grade level of the welding seam is ensured. The popularization and the application of the scheme are beneficial to ensuring the appearance standardization of the welding seam of series products and the consistency and the stability of the welding quality.
The example calculation results by the above method are:
(1) a base metal with the thickness of 4mm, a 60-degree V-shaped groove, no truncated edge and a gap of 2mm are butted, the welding current is 150A, and when the welding speed is 7mm/s, the total number of welding passes required for filling the welding seam is 2, so that one bottoming and one capping can be arranged, the remaining height of the welding seam is less than 1.66mm, and the consumption of welding wires is about 77.8g when the length of the welding seam is 400 mm;
(2) a base metal with the thickness of 10mm, a 60-degree V-shaped groove, no truncated edge and a gap of 2mm are butted, welding current is 120A, when the welding speed is 3.3mm/s, the total number of welding passes required for filling the welding line can be calculated to be 6, therefore, three layers can be arranged, the 1 st pass is bottoming, the 2 nd and 3 rd passes are positioned in the middle layer for filling, the 4 th, 5 th and 6 th passes are positioned on the top cover surface, the residual height of the welding line is less than 2.35mm, and the consumption of the welding wire is about 310g when the length of the welding line is 400 mm;
(3)30mm thick base metal, 60V type groove, 2mm blunt sides, 2mm clearance, butt joint, welding current adopts 270A, when welding speed 5mm/s, can calculate to fill up the welding seam and need the total number of welding bead 21, can arrange six layers from this, the 1 st is bottomed, 2 nd-15 th is located middle four layers and is filled, 16 th-21 th is located the top cap, the surplus height of welding seam is less than 4.43mm, welding wire consumption is about 1.92kg when welding seam length is 400 mm.
The invention relates to a parameterized multi-layer and multi-pass welding bead design method, which is used for realizing the accurate planning of multi-layer and multi-pass welding beads and comprises the quantitative prediction of welding beads and the arrangement planning of welding beads. On one hand, the standardization level of the welding process design is improved, and a foundation is laid for digitization and intellectualization; on the other hand, fine management of the welding production process can be realized, the consistency of product quality is improved, meanwhile, accurate prediction of the consumption of welding materials can be realized, and the scientificity and the high efficiency of material management are improved.
In the prior art, the height of each welding bead is usually fixed, and equal-area division is carried out layer by layer, so that the problem of over-ideal design exists, and the practical operation is unlikely to be the same. The area of each welding seam can be calculated through welding parameters (the areas can be different when the welding parameters are different), the total number of welding passes is determined, the specific height and the included number of the welding layers are planned preliminarily, and filling and layering are carried out according to actual conditions until the welding passes are filled.
In the description of the present application, it is to be understood that the terms "central," "longitudinal," "lateral," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like are used in the orientations and positional relationships indicated in the drawings for the convenience of description and simplicity of 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 considered limiting of the claimed invention.
The above description is only a preferred embodiment of the present invention, and the present invention is not limited to the content of the embodiment. It will be apparent to those skilled in the art that various changes and modifications can be made within the technical scope of the present invention, and any changes and modifications made are within the protective scope of the present invention.
Claims (10)
1. A design method of multilayer multi-pass welding bead is characterized in that: comprises the following steps
Acquiring a total filling sectional area S, and acquiring the total filling sectional area S of the welding wire when the maximum allowable value of the residual height is acquired according to the size of the welding groove;
obtaining the sectional area S occupied by the single welding seam1Obtaining the sectional area S occupied by the single welding line according to the diameter d of the welding wire, the wire feeding speed delta and the welding speed upsilon1；
Obtaining the total number n of welding beads according to the total filling sectional area S and the sectional area S occupied by the single welding bead1Obtaining the total number n of welding beads;
and designing a welding bead according to the total number n of the welding beads.
2. The method of designing a multi-layer, multi-pass weld bead of claim 1, wherein: the welding groove is a V-shaped groove, and the size of the welding groove comprises a groove angle theta, a truncated edge e and a gap width a; the method for calculating the total filling sectional area S of the welding wire comprises the following steps:
a obtaining weld fusion width b
In the formula: a is the gap width, t is the workpiece thickness, e is the truncated edge, and theta is the bevel angle;
b obtaining the total filling sectional area S of the welding wire
In the formula: lambda is equivalent coefficient, b is weld fusion width, h is weld residual height, a is gap width, t is workpiece thickness, e is truncated edge, and theta is groove angle.
3. The method of designing a multi-layer, multi-pass weld bead of claim 1, wherein:
when the welding groove is a V-shaped groove, designing welding beads according to the total number n of the welding beads as follows: the number of welding beads increases gradually from the bottoming layer to the top layer, wherein the bottoming layer is the welding bead arranged in the lowest layer in the welding seam.
4. The method of designing a multi-layer, multi-pass weld bead of claim 3, wherein: the weld reinforcement h satisfies h is less than or equal to 1+0.1b, and h is not more than 5 mm.
5. The method of designing a multi-layer, multi-pass weld bead of claim 1, wherein: the wire feeding speed delta is obtained by the following formula
δ＝k1I+k2
In the formula: k is a radical of1Is a linear proportionality coefficient, k2Is constant, I is welding powerAnd (4) streaming.
6. The multilayer multipass bead design method according to claim 1 or 5, wherein: area S occupied by single welding seam1Is calculated by
In the formula: d is the diameter of the welding wire, delta is the wire feeding speed, and upsilon is the welding speed.
7. The method of designing a multi-layer, multi-pass weld bead of claim 1, wherein: the welding interface is one of V type, U type, X type, unilateral V type, K type.
8. The method of designing a multi-layer, multi-pass weld bead of claim 1, wherein: the total number of passes n is obtained by
Wherein eta is a welding wire loss correction coefficient, S is a total filling sectional area, S1The area of the single welding line is the sectional area occupied by the single welding line.
9. The method of designing a multi-layer, multi-pass weld bead of claim 1, wherein: also comprises the step of obtaining the welding wire quality M required by the welding seam,
in the formula, rho is welding wire density, d is welding wire diameter, delta is wire feeding speed, upsilon is welding speed, and L is0Is the weld length.
10. The method of designing a multi-layer, multi-pass weld bead of claim 1, wherein: the maximum allowable value of the residual height is the maximum allowable value of the residual height meeting the B-grade quality requirement of the welding seam in ISO 5817.
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| CN113231738A (en) * | 2021-06-03 | 2021-08-10 | 苏州大学 | Wire feeding method for laser welding |
| CN114888496A (en) * | 2022-06-30 | 2022-08-12 | 中船黄埔文冲船舶有限公司 | Method and device for predicting quantity of medium-assembly welding wires |
| CN115502601A (en) * | 2022-10-27 | 2022-12-23 | 湘潭大学 | Multilayer and multi-pass welding track optimization method for medium plate based on deposition size |
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Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN113231738A (en) * | 2021-06-03 | 2021-08-10 | 苏州大学 | Wire feeding method for laser welding |
| CN114888496A (en) * | 2022-06-30 | 2022-08-12 | 中船黄埔文冲船舶有限公司 | Method and device for predicting quantity of medium-assembly welding wires |
| CN114888496B (en) * | 2022-06-30 | 2023-08-29 | 中船黄埔文冲船舶有限公司 | Method and device for predicting amount of middle-group welding wire |
| CN115502601A (en) * | 2022-10-27 | 2022-12-23 | 湘潭大学 | Multilayer and multi-pass welding track optimization method for medium plate based on deposition size |
| CN115502601B (en) * | 2022-10-27 | 2023-08-22 | 湘潭大学 | Multilayer multi-channel welding track optimization method for medium plate based on deposition size |
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Application publication date: 20210223 |