CN112935686A - Welding device for breakage of large inclined roll shaft of ring rolling mill and repairing process thereof - Google Patents
Welding device for breakage of large inclined roll shaft of ring rolling mill and repairing process thereof Download PDFInfo
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- CN112935686A CN112935686A CN202110319122.7A CN202110319122A CN112935686A CN 112935686 A CN112935686 A CN 112935686A CN 202110319122 A CN202110319122 A CN 202110319122A CN 112935686 A CN112935686 A CN 112935686A
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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
- B23K37/047—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work moving work to adjust its position between soldering, welding or cutting steps
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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
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Abstract
The invention discloses a large-scale oblique roller shaft fracture welding device of a ring rolling mill, which comprises: the structural part fixing support is used for obliquely placing the inclined roll shaft and enabling the inclined roll shaft to rotate on the structural part fixing support at will; the assembly fixing structure part tool is used for assembling and fixing the fracture part of the inclined roll shaft and controlling the deformation in the welding process; and the heating tool is used for heating the fracture part of the inclined roll shaft. The invention also discloses a welding repair process for the breakage of the large inclined roll shaft of the ring rolling mill based on the welding device. By implementing the invention, a large amount of overhaul time can be shortened, the maintenance cost is reduced, the failure rate shutdown loss is reduced, and the guarantee is provided for reasonable production assembly.
Description
Technical Field
The invention belongs to the technical field of welding, and relates to a welding device for breakage of a large inclined roll shaft of a ring rolling mill and a repair process thereof.
Background
The production process of the ring parts of the horse steel with various specifications comprises the steps of cutting qualified raw material steel ingots into required lengths by sections through a machine tool, heating the cut steel ingots to reach the process temperature by a heating annular furnace, clamping the steel ingots to a hydraulic press for upsetting and perforating through a movable manipulator, clamping the steel ingots by a fixed manipulator for perforating, and then conveying the steel ingots to a ring part rolling mill for rolling and forming. The ring rolling mill mainly comprises a vertical rotary main roller, an upper inclined roller shaft and a lower inclined roller shaft which can move horizontally and a holding roller, wherein the vertical rotary main roller and the holding roller mainly control the wall thickness and the diameter of a ring, and the upper inclined roller shaft and the lower inclined roller shaft which move horizontally control the axial height of the ring. The upper and lower inclined roll shafts are metallurgically combined into a whole by a matrix 42CrMo, a welding transition layer and a hard alloy surface layer (flux-cored wire welding configured according to rolling requirements and various performances), the production process requirements can be normally and completely met, after the surface layer is used for a period of time, the defects of local cracking, abrasion, falling off and the like of the surfaces of the upper and lower inclined roll shafts are caused by the welding quality of the welding layer and stress generated by cold and heat exchange in the using process, particularly, the local cracking position of the surface is continuously rolled and operated along with the production process, the cracking crack is continuously deepened, the effective sectional area of the inclined roll shaft is reduced, the performance requirements of the original inclined roll shaft are not met, and the stress position of the rolling crack is cracked, so that the production stop state is caused. If a new spare part is replaced, the time is generally 2-3 months, and if the spare part is off-line transported to a manufacturer for repair, the repair cycle is long. Therefore, the large inclined roll shaft of the ring rolling mill with the fracture needs to be repaired aiming at the existing situation.
At present, various roll shaft abrasion, fracture and falling welding repair applications are common, and various off-line repair descriptions are provided in many documents, but the documents for the welding repair of the large inclined roll shaft fracture of the ring rolling mill are not disclosed, and the main difficulty of the welding repair of the large inclined roll shaft fracture of the ring rolling mill lies in that the welding defect of the large inclined roll shaft fracture of the ring rolling mill is solved by strictly controlling key process parameters such as welding line energy, fusion ratio, preheating, post-heating, interlayer temperature, metallurgical bonding of a base metal, a transition layer and a hard alloy adjacent base layer weld bead, filling thickness and the like in welding construction. In addition, the surface of the large-sized broken inclined roll shaft after welding repair also meets the following requirements: 1. the conforming panel is inspected to the conforming running size by hand grinding. 2. The metallurgically bonded weld layer is suitable for periodic use. 3. Ensuring the running rolling quality.
Disclosure of Invention
Aiming at the difficulty of welding and repairing the breakage of the large inclined roll shaft of the ring rolled piece in the background technology, the invention provides the device for welding the breakage of the large inclined roll shaft of the ring rolling mill and the repairing process and implements the device.
The technical scheme for solving the technical problem of the invention is as follows:
the invention discloses a large-scale oblique roller shaft fracture welding device of a ring rolling mill, which is characterized by comprising the following components: the structural part fixing support is used for obliquely placing the inclined roll shaft and enabling the inclined roll shaft to rotate on the structural part fixing support at will; the assembly fixing structure part tool is used for assembling and fixing the fracture part of the inclined roll shaft and controlling the deformation in the welding process; and the heating tool is used for heating the fracture part of the inclined roll shaft.
Furthermore, the structural member fixing support comprises a U-shaped supporting frame, a U-shaped supporting box is arranged at the top end of one side of the U-shaped supporting frame, a U-shaped groove is formed in the top of the U-shaped supporting box, a plurality of rollers are uniformly distributed on the U-shaped supporting box, and a fixing ejector pin is obliquely arranged on the other side of the U-shaped supporting box in the direction towards the U-shaped supporting box.
Furthermore, the bottom of the U-shaped supporting box is fixedly connected with the supporting frame through a first pin shaft, and the roller is fixedly connected with the U-shaped supporting box through a second pin shaft; the fixed thimble is fixed on a bolt base in a threaded manner, and the bolt base is fixed on the top of the other side of the supporting frame through a third pin shaft.
Further, the angle formed by the fixed thimble and the horizontal plane is 45 degrees.
Further, the assembly fixed structural part tool comprises a conical frame cage body and a fixed flange, wherein the bottom of the conical frame cage body and the fixed flange are correspondingly arranged and detachably connected and fixed through a plurality of locking screws.
Further, the heating tool comprises two gas pipelines which are correspondingly arranged, and a plurality of nozzles are uniformly arranged on each gas pipeline.
Another technical solution to solve the technical problem of the present invention is as follows:
based on the technical scheme, the repair process of the large inclined roller shaft fracture welding device for the ring rolling mill is used for welding repair of fractured inclined roller shafts, each inclined roller shaft comprises a fractured shaft front end and a shaft connecting part, and the joint of the fractured shaft front end and the shaft connecting part is a fracture part to be repaired, and is characterized by comprising the following steps:
firstly, welding pretreatment of a weldment; firstly, respectively arranging bevel surfaces at a part to be repaired, which is fractured, of the front end of a fractured shaft and a shaft connecting part, then placing the front side of a diagonal roll shaft on a roller of a U-shaped supporting box of a structural member fixing support in an angle of 45 degrees, sleeving the rear end of the diagonal roll shaft on a fixing thimble, enabling the diagonal roll shaft to rotate freely on the structural member fixing support, then installing a group assembly fixture at the front end of the diagonal roll shaft, assembling the front end of the fractured shaft and the shaft connecting part to form a U-shaped groove, finally fixedly installing a heating fixture, and horizontally and symmetrically placing two rows of nozzles on two gas pipelines at the part to be repaired, which is fractured, of the front end of the diagonal roll shaft;
step two, preparing before welding;
2.1), welding equipment: HT400D digital control inversion type manual shielded metal arc welding and argon arc welding are combined by using a direct current welding machine; the hard alloy layer is welded by adopting a CAG-CO21 welding wire, and the purity of argon is more than or equal to 99.999 percent; the transition layer is welded by adopting a BS-308Z welding rod; welding a base metal layer by using an E5015 welding rod, baking the welding rod at 350-400 ℃ for 2 hours, keeping the temperature constant, and taking the welding rod at any time;
2.2), heating device: an oxyacetylene bottle, an electric heating belt;
2.3), auxiliary facilities: angle grinder, file, hammer, flat shovel, mask, heat-insulating barrel, sample plate, thermodetector, magnifier, heat-insulating cotton, plasma gouging LGK-100 MA;
2.4), weldment material: the base material layer 42CrMo, the transition layer stainless steel 304 and the outer layer hard alloy steel;
2.5), groove form: machining a U-shaped groove;
2.6), welding position: welding at 45 degrees;
2.7), welding requirements: all welding layers must be free of any welding defects and fused to the base material;
2.8), cleaning before welding: removing water and oil at the part to be repaired by using oxyacetylene flame, and then polishing and derusting by using an abrasive cloth or a grinding wheel machine;
2.9), determining welding process parameters according to welding materials and welding equipment;
step three, welding and repairing;
3.1), considering the butt welding particularity of the broken part of the oblique roll shaft, wherein a gap is reserved during assembly due to the fact that a circular U-shaped groove is paired, so that a large-diameter welding rod can be conveniently penetrated through the root part, then spot welding is carried out for butt joint, after the integral butt joint meets the welding technical specification, oxygen and acetylene are used for baking the broken part to be repaired and two sides of the U-shaped groove to remove oil dirt, impurities, water and the like, then a heating tool is used for uniformly heating the front end of the oblique roll shaft, the rear end of the oblique roll shaft is subjected to heat preservation by adopting a heat preservation cotton bag, the welding heating area and two sides of the groove are completely covered, when the broken part to be repaired is heated to 500 +/-20 ℃, the U-shaped groove is separated, the rest parts are covered by the heat preservation cotton;
3.2) when welding is carried out, in order to ensure that the welding deformation is controlled within the using range of the oblique roller shaft, the bottom layer of the base metal is primed and covered with a surface layer, two welding machines are used for carrying out arc welding symmetrical welding by adopting manual welding rods, one welding machine carries out welding from the position of 5 points to the position of 9 points to the position of 1 point, the other welding machine waits for the bottom layer to be welded from the position of 7 points to the position of 11 points after one-time welding is finished, the interlayer temperature is controlled to be 400 +/-50 ℃ during welding, a strip conveying method adopts a crescent shape, not only the root part needs to be melted through, but also the base metal bodies on the two sides need to be melted, and a gas shovel is; after the base metal layer is welded and no welding defect is confirmed, manual shielded metal arc welding of the transition layer is carried out, only one layer is welded in the same welding mode as the base metal layer, the thickness of the welding layer is controlled to be 5-8 mm, fusion of the upper connecting layer and the lower connecting layer is guaranteed, and after welding is finished, the surface of the transition layer is polished and flattened by a manual angle grinder, so that the welding of the hard alloy outer layer is facilitated; the surface layer of the oblique roller shaft adopts the same welding mode as the base metal layer, two welding machines adopt manual argon arc welding for symmetrical welding, because the bevel face is wider, the cover face is welded along the shaft diameter in multiple layers and multiple paths, two sides of the groove are fused with the original body material, if welding defects such as cracks occur in the welding process, plasma gouging LGK-100MA is immediately adopted for back chipping, then welding repair is carried out, and the cover face layer is higher than the original surface of the oblique roller shaft; after welding, after a magnifying glass and surface coloring are adopted to detect that welding seams have no welding defects, the welding is carried out by a heating tool, the whole body is heated to 800-950 ℃ after welding, the temperature is kept for 8 hours, then the temperature is gradually reduced to 250 ℃ at the speed of 30 ℃/h, then the temperature is cooled to room temperature, finally, after the detection and flaw detection confirm that no defects exist, a manual angle grinder is adopted to accurately grind and process, and the welding seam is delivered for use after being detected to be qualified.
Furthermore, when the base material layer is welded, an E5015 welding rod with the diameter of 4.0mm is adopted, the welding current is 90-160A, the arc voltage is 23 +/-1V, and the welding speed is 17 +/-1 cm/min; when the transition layer is welded, a BS-308Z welding rod with the diameter of 4.0mm is adopted, the welding current is 80-140A, the arc voltage is 24 +/-1V, and the welding speed is 15 +/-1 cm/min; when the hard alloy layer is welded, a CAG-CO21 welding wire with the diameter of 4.0mm is adopted, the welding current is 170-190A, the arc voltage is 26 +/-1V, and the welding speed is 5 +/-1 cm/min.
Furthermore, when the U-shaped grooves are paired, a gap of 4-8mm is reserved; during spot welding butt joint, the 3 points of the spot welding part are respectively 9 points, 12 points and 3 points, and the starting point of the welding point is 6 points.
Further, before welding, when the front end of the inclined roller shaft is heated by the heating tool, the temperature rises uniformly at 40 ℃/h, and the temperature measuring instrument measures once per hour.
Compared with the prior art, the welding device and the repair process for the large inclined roller shaft fracture of the ring rolling mill have the advantages that the welding device is novel in structure, compact and reasonable in configuration, convenient to manufacture, good in stability, low in investment and small in occupied space, and adopts welding and machining; the repair process based on the welding device is safe and easy to operate, stable in welding quality, low in investment cost, high in working efficiency, capable of meeting the actual requirements on site, greatly reduced in maintenance cost, reduced in shutdown loss, and capable of guaranteeing reasonable production and providing scientific reference basis for welding repair of other large-sized workpieces.
Drawings
FIG. 1 is a schematic view of a welding apparatus according to the present invention;
FIG. 2 is an exploded view of the structural member mounting bracket of the present invention;
FIG. 3 is a schematic view of a tooling for assembling a fixed structural member according to the present invention;
FIG. 4 is a schematic view of a heating tool of the present invention;
FIG. 5 is a schematic structural view of a skew roller shaft provided with a groove according to the present invention;
in the figure: 1. a skew roll shaft; 11. a shaft connecting portion; 12. a front end of a fracture shaft; 13, a U-shaped groove; 2. a structural member fixing bracket; 21. a support frame; 22. a U-shaped pallet; 23. a first pin shaft; 24. a roller; 25. a second pin shaft; 26. fixing the thimble; 27. a bolt base; 28. a third pin shaft; 3. assembling and fixing a structural part tool; 31. a conical frame cage; 32. a fixed flange; 33. locking the screw rod; 4. heating the tool; 41. a gas conduit; 42. and (4) a nozzle.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Unless defined otherwise, technical or scientific terms used herein shall have the ordinary meaning as understood by one of ordinary skill in the art to which this disclosure belongs. The terms "upper", "lower", "left", "right", "front", "rear", and the like used in the specification and claims of the present disclosure are used only to indicate relative positional relationships, and when the absolute position of a described object is changed, the relative positional relationships are changed accordingly.
Example 1:
as shown in fig. 1 to 5, the device for welding a large inclined roll shaft of a ring rolling mill to break according to the present invention comprises a structural member fixing bracket 2, a group assembling fixing structural member tool 3 and a heating tool 4; the structural member fixing support 2 is used for obliquely placing the inclined roll shaft 1 and enabling the inclined roll shaft 1 to rotate on the structural member fixing support 2 at will, and the inclined roll shaft 1 is obliquely placed on the structural member fixing support at an angle of 45 degrees generally; the assembly fixing structural part tool 3 is used for assembling and fixing the fracture part of the inclined roll shaft 1 and controlling the deformation in the welding process, and is matched with the shape of the front end of the inclined roll shaft 1; and the heating tool 4 is used for heating the broken part of the inclined roller shaft 1 before welding and performing heat treatment after welding.
In this embodiment, structure fixed bolster 2 is including the whole braced frame 21 that is "U" shape, this braced frame 21 adopts 50mm steel sheet welding preparation to form, braced frame 21 left side top is provided with U-shaped support box 22, U-shaped groove and equipartition are provided with a plurality of gyro wheels 24 have been seted up at this U-shaped support box 22's top, braced frame 21 right side is provided with fixed thimble 26 towards the slope of U-shaped support box 22 direction, fixed thimble 26 generally becomes 45 jiaos with the horizontal plane, a rear end center department for fixed oblique roller 1, the oblique roller 1 of being convenient for inclines 45 degrees on structure fixed bolster 2 and places. Further, the bottom of the U-shaped pallet 22 is fixedly connected with the supporting frame 21 through a first pin 23, and the roller 24 is fixedly connected with the U-shaped pallet 22 through a second pin 25; the fixed thimble 26 is screwed to a bolt base 27, and the bolt base 27 is fixed to the top of the other side of the support frame 21 by a third pin 28.
In this embodiment, group to fixed knot spare frock 3 adopt 30mm steel sheet machining and welding preparation to form, it includes the conical frame cage body 31 and mounting flange 32, the corresponding setting of this conical frame cage body 31 bottom and mounting flange 32 is fixed through the detachable connection of a plurality of locking screw 33, be convenient for carry out the group to the fracture department of 1 front end of oblique roll-spindle to fixed and control the deflection in the welding repair process.
In this embodiment, the heating tool 4 is made of a steel pipe with a diameter of 50mm, and includes two gas pipelines 41 correspondingly disposed, and each gas pipeline 41 is uniformly provided with a plurality of nozzles 42. When the heating device is used, the heating device 4 can be movably connected and fixed on a door-shaped frame (a conventional structure, not shown in the attached drawing) made of 40mm angle steel, the bottom surface of the door-shaped frame is horizontally placed on the ground, and the position of the heating device 4 can be adjusted on the door-shaped frame, so that the heating positions of the two rows of nozzles 42 on the two sides can be adjusted at any time.
Example 2:
as shown in fig. 1 to 5, a repair process of a large-scale oblique roller shaft breakage welding device of a ring rolling mill based on embodiment 1 is used for welding repair of a broken oblique roller shaft 1, the oblique roller shaft 1 is broken into a broken shaft front end 12 and a shaft connecting part 11 in long-term operation, a connection part of the broken shaft front end 12 and the shaft connecting part 11 is a breakage to-be-repaired part, and the welding repair process includes the following steps:
firstly, welding pretreatment of a weldment; firstly, respectively arranging bevel face surfaces at the positions to be repaired of the fracture at the front end 12 of a fracture shaft and a shaft connecting part 11, then placing the front side of an inclined roll shaft 1 on a roller 24 of a U-shaped supporting box of a structural part fixing support 2 in an angle of 45 degrees, sleeving the rear end of the inclined roll shaft 1 on a fixing thimble 26, enabling the inclined roll shaft 1 to rotate freely on the structural part fixing support 2, then installing a group-to-fixing structural part tool 3 at the front end of the inclined roll shaft 1, assembling the front end 12 of the fracture shaft and the shaft connecting part 11 to form a U-shaped groove 13, reserving a gap of 4-8mm between the front end 12 of the fracture shaft and the shaft connecting part 11 during assembling, finally fixedly installing a heating tool 4, and horizontally and symmetrically arranging two rows of nozzles 42 on two gas pipelines 41 at the positions to be repaired of the fracture at the front end of the inclined roll shaft;
step two, preparing before welding;
2.1, welding equipment: HT400D digital control inversion type manual shielded metal arc welding and argon arc welding are combined by using a direct current welding machine; the hard alloy layer is welded by adopting a CAG-CO21 welding wire, and the purity of argon is more than or equal to 99.999 percent; the transition layer is welded by adopting a BS-308Z welding rod; welding a base metal layer by using an E5015 welding rod, baking the welding rod at 350-400 ℃ for 2 hours, keeping the temperature constant, and taking the welding rod at any time;
2.2, heating device: an oxyacetylene bottle, an electric heating belt;
2.3, auxiliary facilities: angle grinder, file, hammer, flat shovel, mask, heat-insulating barrel, sample plate, thermodetector, magnifier, heat-insulating cotton, plasma gouging LGK-100 MA;
2.4, weldment material: the base material layer 42CrMo, the transition layer stainless steel 304 and the surface layer hard alloy steel;
2.5, groove form: machining a U-shaped groove;
2.6, welding position: welding at 45 degrees;
2.7, welding requirement: all welding layers must be free of any welding defects and fused to the base material;
2.8, cleaning before welding: removing water and oil at the part to be repaired by using oxyacetylene flame, and then polishing and derusting by using an abrasive cloth or a grinding wheel machine;
2.9, determining welding process parameters according to welding materials and welding equipment;
welding process parameters
Step three, welding and repairing;
3.1, considering the particularity of butt welding at the fracture part of the oblique roll shaft 1, because the oblique roll shaft is assembled by circular U-shaped grooves, a gap of 4-8mm is reserved during assembly, the root part of a large-diameter welding rod can be conveniently melted through, then the oblique roll shaft is butted by spot welding, 3 points of the spot welding part are respectively 9 points, 12 points and 3 points, the spot welding is fixed, after the integral butt joint meets the welding technical specification, oxygen and acetylene are used for baking the fracture part to be repaired and two sides of the U-shaped groove 13 to remove oil stain, impurities, moisture and the like, then a heating tool 4 is used for uniformly heating the front end of the oblique roll shaft 1, the rear end of the oblique roll shaft 1 is wrapped by heat-preserving cotton for heat preservation, the temperature is required to rise uniformly by 40 ℃/h during heating, a temperature measurer measures once per hour, the welding heating area and two sides of the groove are all covered, thus the local temperature difference stress can be, preventing or reducing the formation of hardened structures; when the part to be repaired of the fracture is heated to 500 +/-20 ℃, separating the U-shaped groove 13, covering the rest parts with heat preservation cotton, continuing heating and heat preservation by the heating tool 4, and then performing welding;
3.2, when welding is carried out, in order to ensure that the welding deformation is controlled within the use range of the oblique roll shaft 1, bottoming and covering layers of the base metal bottom layer are symmetrically welded by adopting manual welding rod arc welding through two welding machines, one welding machine welds from the position of 5 points to the position of 9 points to the position of 1 point, the other welding machine welds from the position of 7 points to the position of 11 points after the bottom layer is welded for one time, the interlayer temperature is controlled to be 400 +/-50 ℃ during welding, a strip conveying method adopts a crescent shape, not only the root part needs to be thoroughly melted, but also the base metal bodies on two sides need to be well fused, and a gas shovel is adopted to clear molten slag and eliminate part of welding stress after each layer of welding; after the base material layer is welded and no welding defect is confirmed, manual shielded metal arc welding of the transition layer is carried out, only one layer is welded in the same welding mode as the base material layer, the thickness of the welding layer is controlled to be 5-8 mm to ensure fusion of the upper connecting layer and the lower connecting layer, and the surface of the transition layer is polished and flattened by a manual angle grinder after welding is finished, so that the surface layer of the hard alloy can be conveniently welded; the surface layer of the oblique roller shaft 1 adopts the same welding mode as the base metal layer, two welding machines adopt manual argon arc welding for symmetrical welding, because the bevel face is wider, the cover face is welded along the shaft diameter in multiple layers and multiple paths, two sides of the groove are fused with the original body material, if welding defects such as cracks occur in the welding process, plasma gouging LGK-100MA is immediately adopted for back chipping, then welding repair is carried out, and the cover face layer is higher than the original surface of the oblique roller shaft 1; after welding, after a magnifying glass and surface coloring are adopted to detect that a welding seam has no welding defects, the heating tool 4 is used for carrying out post-welding annealing and overall heating to 800-950 ℃, the temperature is kept for 8 hours, then the temperature is gradually reduced to 250 ℃ at the speed of 30 ℃/h, then the temperature is cooled to room temperature, finally, after the detection and flaw detection confirm that no welding defects exist, a manual angle grinder is used for accurate grinding processing, a sample plate which is manufactured firstly can be used for comparison, and the use tolerance size is recovered.
The invention is applied to welding repair on a large-scale oblique roller shaft broken by a certain steel ring rolling mill, the butt joint U-shaped groove of the oblique roller shaft is successfully welded by the combination of manual shielded metal arc welding and argon arc welding, the rotating requirement of the integral oblique roller shaft is completely met through sample plate inspection and acceptance, the oblique roller shaft is put into service, the mechanical performance effect is achieved through periodic operation, and the oblique roller shaft has good practicability and is worthy of popularization.
Claims (10)
1. The utility model provides a large-scale skewed roll axle fracture welding set of ring spare rolling mill which characterized in that includes:
the structural part fixing support (2) is used for obliquely placing the inclined roll shaft (1) and enabling the inclined roll shaft (1) to rotate on the structural part fixing support (2) at will;
the assembly fixing structural part tool (3) is used for assembling and fixing the fracture part of the diagonal roll shaft (1) and controlling the deformation in the welding process; and
and the heating tool (4) is used for heating the fracture part of the inclined roll shaft (1).
2. The large-scale oblique roller shaft fracture welding device of a ring rolling mill according to claim 1, characterized in that the structural member fixing support (2) comprises a support frame (21) which is integrally shaped like a U, a U-shaped supporting box (22) is arranged at the top end of one side of the support frame (21), a U-shaped groove is formed in the top of the U-shaped supporting box (22), a plurality of rollers (24) are uniformly distributed on the U-shaped supporting box, and a fixing thimble (26) is obliquely arranged on the other side of the support frame (21) towards the U-shaped supporting box (22).
3. The large oblique roller shaft fracture welding device of the ring rolling mill according to claim 2, characterized in that the bottom of the U-shaped supporting box (22) is fixedly connected with the supporting frame (21) through a first pin shaft (23), and the roller (24) is fixedly connected with the U-shaped supporting box (22) through a second pin shaft (25); the fixed thimble (26) is fixed on a bolt base (27) in a threaded manner, and the bolt base (27) is fixed on the top of the other side of the supporting frame (21) through a third pin shaft (28).
4. The large skew roll axis rupture welding apparatus of ring mill according to any one of claims 1-3, wherein the angle of the fixed thimble (26) with the horizontal plane is 45 °.
5. The large-scale oblique roller shaft fracture welding device of the ring rolling mill according to claim 4, characterized in that the assembly fixing structure tool (3) comprises a conical frame cage body (31) and a fixing flange (32), and the bottom of the conical frame cage body (31) and the fixing flange (32) are correspondingly arranged and detachably connected and fixed through a plurality of locking screws (33).
6. The large inclined roller shaft fracture welding device of the ring rolling mill according to claim 5, characterized in that the heating tool (4) comprises two correspondingly arranged gas pipelines (41), and each gas pipeline (41) is uniformly provided with a plurality of nozzles (42).
7. The repair process of the broken welding device of the large inclined roll shaft of the ring rolling mill based on any one of the claims 1 to 6 is used for welding repair of the broken inclined roll shaft (1), the inclined roll shaft (1) comprises a broken shaft front end (12) and a shaft connecting part (11), and the joint of the broken shaft front end (12) and the shaft connecting part (11) is a broken part to be repaired, and is characterized by comprising the following steps:
firstly, welding pretreatment of a weldment; firstly, respectively arranging bevel surfaces at a fracture part to be repaired on the front end (12) of a fracture shaft and a shaft connecting part (11), then placing the front side of an inclined roll shaft (1) on a roller (24) of a U-shaped supporting box of a structural part fixing support (2) at an angle of 45 degrees, sleeving the rear end of the inclined roll shaft (1) on a fixing thimble (26), enabling the inclined roll shaft (1) to rotate on the structural part fixing support (2) at will, then installing a group-to-fixing structural part tool (3) at the front end of the inclined roll shaft (1), assembling the front end (12) of the fracture shaft and the shaft connecting part (11) to form a U-shaped groove (13), finally fixedly installing a heating tool (4), and horizontally and symmetrically arranging two rows of nozzles (42) on two gas pipelines (41) at the part to be repaired at the front end of the inclined roll shaft (1);
step two, preparing before welding;
2.1), welding equipment: HT400D digital control inversion type manual shielded metal arc welding and argon arc welding are combined by using a direct current welding machine; the hard alloy layer is welded by adopting a CAG-CO21 welding wire, and the purity of argon is more than or equal to 99.999 percent; the transition layer is welded by adopting a BS-308Z welding rod; welding a base metal layer by using an E5015 welding rod, baking the welding rod at 350-400 ℃ for 2 hours, keeping the temperature constant, and taking the welding rod at any time;
2.2), heating device: an oxyacetylene bottle, an electric heating belt;
2.3), auxiliary facilities: angle grinder, file, hammer, flat shovel, mask, heat-insulating barrel, sample plate, thermodetector, magnifier, heat-insulating cotton, plasma gouging LGK-100 MA;
2.4), weldment material: the base material layer 42CrMo, the transition layer stainless steel 304 and the outer layer hard alloy steel;
2.5), groove form: machining a U-shaped groove;
2.6), welding position: welding at 45 degrees;
2.7), welding requirements: all welding layers must be free of any welding defects and fused to the base material;
2.8), cleaning before welding: removing water and oil at the part to be repaired by using oxyacetylene flame, and then polishing and derusting by using an abrasive cloth or a grinding wheel machine;
2.9), determining welding process parameters according to welding materials and welding equipment;
step three, welding and repairing;
3.1), considering the butt welding particularity of the fracture part of the oblique roll shaft (1), as a round U-shaped groove is paired, a gap is reserved during pairing so that a large-diameter welding rod can be conveniently penetrated through the root part, then spot welding is carried out for butt joint, after the integral butt joint meets the welding technical specification, oxygen and acetylene are used for baking the fracture part to be repaired and two sides of the U-shaped groove (13) to remove oil stain, impurities, moisture and the like, then a heating tool (4) is used for uniformly heating the front end of the oblique roll shaft (1), the rear end of the oblique roll shaft (1) is subjected to heat preservation by adopting a heat preservation cotton bag bundle, the welding heating area and two sides of the groove are completely covered, when the fracture part to be repaired is heated to 500 +/-20 ℃, the U-shaped groove (13) is separated, the rest parts are covered by the heat preservation cotton, and the heating tool (4);
3.2) when welding is carried out, in order to ensure that the welding deformation is controlled within the use range of the oblique roller shaft (1), bottoming and covering layers of the base metal bottom layer are symmetrically welded by adopting manual welding rod arc welding through two welding machines, one welding machine welds from the position of 5 points to the position of 9 points to the position of 1 point, the other welding machine welds from the position of 7 points to the position of 11 points after the bottom layer is welded for one time, the interlayer temperature is controlled to be 400 +/-50 ℃ during welding, a strip conveying method adopts a crescent shape, not only the root part needs to be thoroughly melted, but also the base metal bodies on two sides need to be well fused, and a gas shovel is adopted to clear molten slag and eliminate partial welding stress after each layer of welding is finished; after the base metal layer is welded and no welding defect is confirmed, manual shielded metal arc welding of the transition layer is carried out, only one layer is welded in the same welding mode as the base metal layer, the thickness of the welding layer is controlled to be 5-8 mm, fusion of the upper connecting layer and the lower connecting layer is guaranteed, and after welding is finished, the surface of the transition layer is polished and flattened by a manual angle grinder, so that the welding of the hard alloy outer layer is facilitated; the surface layer of the oblique roller shaft (1) adopts the same welding mode as the base metal layer, two welding machines adopt manual argon arc welding for symmetrical welding, because the bevel face is wider, the cover face is welded along the shaft diameter in multiple layers and multiple paths, two sides of the groove are fused with the original body material, if welding defects such as cracks occur in the welding process, the back chipping is immediately carried out by adopting a plasma gouging LGK-100MA, then the welding repair is carried out, and the cover face layer is higher than the original surface of the oblique roller shaft (1); after welding, after detecting that a welding seam has no any welding defect by using a magnifying glass and surface coloring, performing postwelding annealing and integral heating to 800-950 ℃ through a heating tool (4), keeping the temperature for 8 hours, then gradually reducing the temperature to 250 ℃ at the speed of 30 ℃/h, cooling to room temperature, finally confirming that no defect exists by detecting and detecting flaws, precisely grinding by using a manual angle grinder, and delivering for use after the defects are detected to be qualified.
8. The repairing process of the large oblique roller shaft fracture welding device of the ring rolling mill according to claim 7, characterized in that an E5015 welding rod with a diameter of 4.0mm is adopted during the welding of the base material layer, the welding current is 90-160A, the arc voltage is 23 +/-1V, and the welding speed is 17 +/-1 cm/min; when the transition layer is welded, a BS-308Z welding rod with the diameter of 4.0mm is adopted, the welding current is 80-140A, the arc voltage is 24 +/-1V, and the welding speed is 15 +/-1 cm/min; when the hard alloy layer is welded, a CAG-CO21 welding wire with the diameter of 4.0mm is adopted, the welding current is 170-190A, the arc voltage is 26 +/-1V, and the welding speed is 5 +/-1 cm/min.
9. The repairing process of the large-scale oblique roller shaft fracture welding device of the ring rolling mill according to claim 7, characterized in that when the U-shaped grooves (13) are paired, a gap of 4-8mm is left; when spot welding is carried out for butt joint, the 3 points of the spot welding part are respectively 9 points, 12 points and 3 points.
10. The repairing process of the large inclined roller shaft breakage welding device of the ring rolling mill according to claim 7, characterized in that before welding, when the front end of the inclined roller shaft (1) is heated by the heating tool (4), the temperature rises uniformly at 40 ℃/h, and the temperature measuring instrument measures once per hour.
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