CN113523510A - Double-vehicle submerged arc welding manufacturing method of seven-stud rotor bracket - Google Patents
Double-vehicle submerged arc welding manufacturing method of seven-stud rotor bracket Download PDFInfo
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- CN113523510A CN113523510A CN202110822942.8A CN202110822942A CN113523510A CN 113523510 A CN113523510 A CN 113523510A CN 202110822942 A CN202110822942 A CN 202110822942A CN 113523510 A CN113523510 A CN 113523510A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/18—Submerged-arc welding
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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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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/20—Hydro energy
Abstract
The invention discloses a double-vehicle submerged-arc welding manufacturing method of a seven-vertical-rib rotor support, belongs to the field of manufacturing of generator rotor supports, and solves the problems that longitudinal welding of 7 vertical ribs and a central body occupies large submerged-arc welding equipment, the welding period is long, the production efficiency is low, the welding cost is high, and the welding deformation control is difficult.
Description
Technical Field
The invention belongs to the field of manufacturing of generator rotor supports, and particularly relates to a double-vehicle submerged arc welding manufacturing method of a seven-stud rotor support.
Background
The rotor support is a key component of the pumped storage generator set, the rotor support is mainly formed by welding and assembling a central body, a stud and other parts, the central body comprises an upper disc, a lower disc and a central cylinder, the welding seams of the upper disc, the lower disc and the central cylinder are circumferential welding seams, and the welding seams of the stud and the central body are longitudinal welding seams. The pumping storage unit rotates forwards and backwards during operation, a water head is large, and the rotating speed is high, so that the requirements on structural design, material selection and manufacturing of a rotor support of the pumping storage unit are strict, the rotor support of the pumping storage unit is greatly different from a mixed flow type unit, the mixed flow type unit comprises more than 20 inclined vertical ribs, the thickness of each inclined vertical rib is small, a steel plate is generally selected, the quantity of the vertical ribs of the pumping storage unit is small, the vertical ribs are generally divided into 6 ribs, 7 ribs or 8 ribs, the magnetic poles are required to be hung in the whole circle outside the vertical ribs, the pumping storage unit is generally made of high-strength forged steel in order to improve the bearing capacity of the vertical ribs, and the vertical ribs are vertical ribs and are large in thickness and can reach 300 mm.
The rotor support has large volume, the weight is more than 50 tons, and the thicknesses of parts of the upper disc, the lower disc, the central cylinder and the stud are large, so that the welding amount of the rotor support is large. In the prior art, submerged arc welding is the most suitable manufacturing method for welding the rotor holder in view of high welding efficiency and the form of the welded structure. The most ideal welding station of submerged-arc welding is flat welding, the flat welding is very favorable for the welding seam quality and the welding seam formation, for the welding of rotor support vertical ribs and a central body longitudinal welding seam of 6 vertical ribs, the central body is driven to rotate by a roller to enable two symmetrical vertical ribs to be in a horizontal state, then a submerged-arc welding trolley is respectively placed on the vertical ribs on the left side and the right side to carry out welding, after a certain welding amount is reached, the central body needs to be continuously rotated to control welding deformation so that the adjacent 2 vertical ribs are perpendicular to the horizontal station, then submerged-arc welding is carried out, the welding of the rotor support 6 vertical ribs longitudinal welding seam is finally realized through the method, and the welding mode of the central body of 8 vertical ribs and the vertical rib longitudinal welding seam is basically the same as that of the 6 vertical ribs.
For a rotor support with 7 vertical bars, the method is introduced in the document ' high-speed generator motor rotor rolling forming and automatic welding process ', ' welding is carried out by adopting a mode of combining rolling tire submerged arc welding and trolley automatic welding, and the specific method comprises the following steps: when the rotor central body rotates to the position shown in the figure 7, an automatic welding trolley is used for welding an upper groove of a welding seam between the 7# rib plate and the central cylinder while an upper groove of the welding seam between the 3# rib plate and the central cylinder is welded by using rolling tire submerged arc welding, the central cylinder is continuously rotated after the welding seam is welded to a specified groove depth, when the 3# rib plate rotates to the position of the original 7# rib plate, the rolling tire submerged arc welding is used for welding a groove on the other side of the welding seam between the 3# rib plate and the central cylinder, the automatic welding trolley is used for welding a groove on the other side of the welding seam between the 7# rib plate and the central cylinder, the welding seams of all the rib plates are repeatedly and circularly welded according to the sequence until the welding seams are fully welded, and the submerged arc welding of the welding seams between the rib plate and the central cylinder is completed. "the rotor support of 7 vertical bars introduced in this document is an asymmetric structure, and only 1 3 vertical bar in a horizontal state can be welded by using a submerged arc welding trolley, and the 7 vertical bar on the other side is in a non-horizontal welding station, and the submerged arc welding trolley can not be used for welding any more, and in the actual welding process, the submerged arc welding can be implemented by using large submerged arc welding equipment with an operation frame, and the number of large submerged arc welding equipment with the operation frame is small, and the occupied area of the field greatly affects the welding of other parts, so that most of the longitudinal seam welding of 7 vertical bar rotor supports can only be completed by 1 submerged arc welding trolley, and the problem of low welding production efficiency of the rotor support exists. In addition, no matter whether the rotor support with 6 vertical bars, 7 vertical bars or 8 vertical bars is in the submerged arc welding process, due to the fact that the submerged arc welding is high in cladding efficiency and large in heat input, welding deformation of the vertical bars relative to the central body often occurs, and the welding deformation is difficult to control, the design requirements of drawings cannot be met, meanwhile, the vertical bar groove form is K-shaped in the original design, the groove welding wire filling amount is large, and the welding cost is high.
Disclosure of Invention
The invention provides a double-vehicle submerged arc welding manufacturing method of a seven-vertical-rib rotor bracket, aiming at overcoming the defects of the prior art and solving the problems that the longitudinal welding seam of 7 vertical ribs and a central body occupies large-scale submerged arc welding equipment, the welding period is long, the production efficiency is low, the welding cost is high, and the welding deformation is difficult to control; the method is realized by the following steps:
the method comprises the following steps: root back sealing, after the welding of the circumferential weld of the central body is finished, vertically placing the central body and the vertical ribs, preheating to-be-welded areas of the central body and the vertical ribs, carrying out back sealing welding of the groove root by adopting gas shielded welding, welding arc-shaped lacing wires between the side planes of the small groove of the vertical ribs and the central body, and simultaneously installing false rings for rolling tires on two sides of the central body;
step two: backing welding is carried out on the large-slope-side, a central body for installing and welding vertical bars is horizontally placed on a rolling die, the 1# vertical bar is adjusted to be in a horizontal state, the large-slope-side faces face upwards, a welding area of the vertical bars and the central body to be welded is preheated to a preset temperature, submerged arc welding backing welding is adopted, the welding thickness is controlled according to 30-40 mm, welding deformation is controlled within a range of 3-5 mm through sample plate detection, the rolling die is rotated anticlockwise, the adjacent vertical bars are enabled to be in the horizontal state in sequence, backing welding of the remaining 6 vertical bar large-slope-side is completed in the same mode, and the welding sequence is as follows: 1# stud → 2# stud → 3# stud → 4# stud → 5# stud → 6# stud → 7# stud;
Step three: back chipping of small groove side, adjustment 1# founds muscle and is in the horizontality, makes the small groove face up, carries out the back chipping to the backing weld of big groove face, polishes after the back chipping and exposes metallic luster, then carries out PT and detects a flaw and ensure that welding seam root defect clears away totally and clear away the arc lacing wire simultaneously, anticlockwise rotation rolls the child, makes the founding muscle that closes on be in the horizontality in proper order, adopts the same mode to accomplish the back chipping of remaining 6 founding muscle small groove sides, and the back chipping order is: 1# stud → 2# stud → 3# stud → 4# stud → 5# stud → 6# stud → 7# stud;
step four: welding at the bottoming of little notch side, adjustment 1# stud is in the horizontality, makes little notch surface up, with stud and central body treat welding zone preheat to the predetermined temperature after, adopt submerged arc welding to bottoming the welding to little notch side, detect control welding deformation with the template at 2 ~ 3mm within ranges, anticlockwise rotation rolls child, makes the stud that closes on be in the horizontality in proper order, adopts the same mode to accomplish the bottoming welding that closes on 2 stud little notch sides, the welding order is: 1# stud 5 → 2# stud 6 → 3# stud 7;
step five: backing welding at the small-groove side and filling welding at the large-groove side, wherein stop blocks are uniformly distributed at positions 50-60 mm away from the groove side edges of the front and back surfaces of all the vertical ribs along the axial direction, at the moment, backing welding of 3 vertical ribs is finished, when backing welding at the small-groove side of a 4# vertical rib is prepared, the large-groove surface of the 1# vertical rib is upward, the backing welding at the small-groove side is finished by considering that the 1# vertical rib can enter a welding seam filling stage, a roller is rotated anticlockwise, the 1# vertical rib and the 4# vertical rib are adjusted to be in an axial symmetry state, a triangular backing plate is arranged on the 1# vertical rib and the 4# vertical rib along the axial direction, a submerged-arc welding trolley and a track are laid on a triangular backing plate, after the welding areas of the vertical ribs and a central body are preheated to a preset temperature, backing welding is carried out on the small-groove side of the 4# vertical rib by adopting submerged-arc welding, welding deformation is detected and controlled to be within a range of 2-3 mm by using a sample plate, and filling welding is carried out on the large-groove side of the 1# vertical rib, and (3) detecting and controlling the welding deformation within 2mm by using a sample plate, completing the backing welding of the small notch side of the remaining 4 vertical ribs and the filling welding of the large notch side of the 1# to 4# vertical ribs by adopting the same mode, wherein the welding sequence is as follows: the No. 4 stud + the No. 1 stud → the No. 5 stud + the No. 2 stud → the No. 6 stud + the No. 3 stud → the No. 7 stud + the No. 4 stud;
Step six: filling and welding, anticlockwise rotating the roller, adjusting the 1# and 4# studs to be in an axisymmetric state, preheating the to-be-welded areas of the studs and the central body to a preset temperature, simultaneously adopting 2 submerged-arc welding trolleys to perform submerged-arc welding filling and welding on the 1# and 4# studs in the axisymmetric state, detecting and controlling welding deformation within 2mm by using a sample plate, anticlockwise rotating the roller to enable adjacent studs to be in the axisymmetric state in sequence, wherein the welding sequence is as follows: 1# stud +4# stud → 2# stud +5# stud → 3# stud +6# stud → 4# stud +7# stud → 5# stud +1# stud → 6# stud +2# stud → 7# stud +3# stud until the weld seam is full;
step seven: transition and capping welding, adopt 2 muscle symmetry mode submerged arc welding equally, detect with the sample board and control welding deformation within 2mm, anticlockwise rotation rolls child, makes the stud that closes on be in the axisymmetric state in proper order, and the welding order is: 1# stud +4# stud → 2# stud +5# stud → 3# stud +6# stud → 4# stud +7# stud → 5# stud +1# stud → 6# stud +2# stud → 7# stud +3# stud until the weld fillet welding is completed;
step eight: and (4) cross inspection, performing VT, UT and MT flaw detection on the welding seams after welding is finished, performing stress relief annealing after the welding seams are qualified, performing VT, UT and MT flaw detection on the welding seams again after annealing, and performing acceptance and next sequence after requirements are met.
In the manufacturing method of the seven-stud rotor bracket by double-vehicle submerged arc welding, in the first step, the central body and the studs are both made of SM 570-F forged pieces, and the false ring for the rolling tire is made of an SM570 steel plate.
In the manufacturing method of the double-vehicle submerged arc welding of the seven-stud rotor support, the preheating temperature of the back cover welding and the false ring installation of the gas shielded welding in the step one is not lower than 100 ℃, the used welding wire is phi 1.2mmAWS ER90S-G, the submerged arc backing welding of a large groove in the step two, the submerged arc backing welding of a small groove in the step three, the submerged arc filling welding in the step four, and the preheating temperature of the submerged arc transition and cover surface stage in the step five are not lower than 120 ℃, and the used welding wire and the used welding flux are respectively phi 4mmAWS F62P4-EA3-A3 and 10-60-mesh AWS 62P4-EA 3-A3.
In the above two-vehicle submerged arc welding manufacturing method for a seven-stud rotor support, the welding specification of the gas shielded welding in the first step is as follows: the current is 210-: 78% Ar + 22% CO2Flow rate: 12-20L/min.
In the above two-vehicle submerged arc welding manufacturing method of the seven-stud rotor support, the welding specification of the large-slope side submerged arc backing welding in the second step is as follows: the current is 450A, the voltage is 30V, and the welding speed is 450-550 mm/min.
In the above manufacturing method of the double-vehicle submerged arc welding of the seven-stud rotor support, the welding specification of the small-slope side submerged arc backing welding in the fourth step is as follows: the current is 450-500A, the voltage is 30-31V, and the welding speed is 450 mm/min.
In the above manufacturing method of the double-vehicle submerged arc welding of the seven-stud rotor support, the welding specifications of the large-slope side submerged arc filling welding in the fifth step and the submerged arc filling welding in the sixth step are as follows: the current 650A, the voltage 32V and the welding speed 350-.
In the above two-vehicle submerged arc welding manufacturing method of the seven-stud rotor support, the welding specifications of submerged arc transition and cover surface welding in the seventh step are as follows: the current is 600A, the voltage is 31-32V, and the welding speed is 350-.
In the above two-vehicle submerged arc welding manufacturing method of the seven-stud rotor support, the welding specification of the last submerged arc transition and the cover surface welding in the seventh step is as follows: the current is 500A, the voltage is 30V, and the welding speed is 500 mm/min.
In the double-vehicle submerged arc welding manufacturing method of the seven-stud rotor support, the large and small groove forms of the studs are fold line transition grooves.
Compared with the prior art, the invention has the following beneficial effects:
the invention provides a double-vehicle submerged-arc welding manufacturing method of a seven-vertical-rib rotor bracket, which realizes the simultaneous welding of two vertical ribs of the seven-vertical-rib rotor bracket by two submerged-arc welding trolleys by utilizing a triangular backing plate, reduces the occupation of large submerged-arc welding equipment, greatly shortens the production and manufacturing period, greatly improves the welding production efficiency of the seven-vertical-rib rotor bracket, simultaneously realizes the symmetrical welding of large and small grooves in different stages of backing welding and filling welding of the vertical ribs by utilizing a reverse deformation method, combining a sample plate and a reasonable welding sequence, effectively controls the welding deformation of a central body and the vertical ribs, has attractive welding seam forming and does not have undercut defects. In addition, the groove form of the stud is changed from the original K-shaped groove into a broken line transition type groove, so that the welding wire filling amount is reduced, and the welding cost is effectively saved.
Drawings
FIG. 1 is a schematic view of a vertical position of a central body and a stud gas-shielded seal-bottom weld in accordance with the present invention;
FIG. 2 is a schematic view of a welding station in a submerged arc backing welding stage of a central body and a large vertical rib notch in the invention;
FIG. 3 is a schematic view of a welding station at a submerged arc backing welding stage of the central body and the small groove of the stud according to the present invention;
FIG. 4 is a schematic view of a welding station in a submerged arc fill welding and transition and capping phase of a central body and studs in the present invention;
FIG. 5 is an enlarged view of a portion of region I of FIG. 4;
FIG. 6 is a schematic view of the welding station during the submerged arc transition and capping stages of the center body and studs of the present invention;
FIG. 7 is a schematic view of the arrangement of the stopper, triangular backing plate and rail;
FIG. 8 is a front schematic view of FIGS. 4 and 6;
FIG. 9 is a left side schematic view of FIG. 8;
FIG. 10 is a schematic diagram of a template structure according to the present invention;
FIG. 11 is a schematic view of a bead fold-line groove according to the present invention.
The notation in the figure is: the steel bar comprises a 1-central body, 2-vertical bars, 3-arc-shaped tie bars, 4-false rings, 5-1# vertical bars, 6-2# vertical bars, 7-3# vertical bars, 8-4# vertical bars, 9-5# vertical bars, 10-6# vertical bars, 11-7# vertical bars, 12-large grooves, 13-small grooves, 14-stop blocks, 15-triangular backing plates, 16-rails, 17-supporting column screws, 18-supporting blocks, 19-supporting plates, 20-steel pipes, 21-sample plates, 22-rolling tires and 23-submerged arc welding trolleys.
Detailed Description
The present application is further described below with reference to the accompanying drawings. The following examples are only for illustrating the technical solutions of the present invention more clearly, and the protection scope of the present application is not limited thereby.
The embodiment provides a double-vehicle submerged arc welding manufacturing method of a seven-stud rotor bracket, which is realized by the following steps:
the method comprises the following steps: root back sealing, as shown in fig. 1, after the central body 1 is welded by circumferential weld, the central body 1 and the vertical ribs 2 are vertically placed, the areas to be welded of the central body 1 and the vertical ribs 2 are preheated, the back sealing of the groove root is carried out by adopting gas shielded welding, an arc-shaped lacing wire 3 is welded between the side plane of the small groove 13 of the vertical ribs 2 and the central body 1, and meanwhile, false rings 4 for rolling tires 22 are arranged on two sides of the central body 1; in the step, the back sealing welding is adopted to prevent the welding flux from leaking from the back surface when the large groove 12 is subjected to submerged arc backing welding, the arc lacing wire is adopted to prevent the welding deformation of the vertical rib 2 when the large groove 12 is subjected to submerged arc backing welding from being overlarge, and the false ring 4 is installed to adjust the relative position of the central body and the vertical rib so as to meet the welding requirements of different welding stations.
Step two: backing welding on the 12 sides of the large grooves, as shown in fig. 2, a central body 1 provided with welding studs 2 is horizontally placed on a roller 4, the 1# stud 5 is adjusted to be in a horizontal state, the 12 sides of the large grooves face upwards, after the welding areas of the studs 2 and the central body 1 are preheated to a preset temperature, submerged arc welding backing welding is adopted, the welding thickness is controlled according to 30-40 mm, a template 21 is used for detecting and controlling the welding deformation within the range of 3-5 mm, the roller 22 rotates anticlockwise, adjacent studs 2 are sequentially in a horizontal state, backing welding on the 12 sides of the large grooves of the remaining 6 studs 2 is completed in the same mode, and the welding sequence is as follows: 1# stud 5 → 2# stud 6 → 3# stud 7 → 4# stud 8 → 5# stud 9 → 6# stud 10 → 7# stud 11; the purpose of controlling the welding thickness according to 30-40 mm in the step is to prevent insufficient weld strength caused by reduced weld section after the weld on the small groove 13 surface is back gouged, and during preheating, the weld root is cracked due to partial release of stress, meanwhile, the anti-deformation method is adopted in the step to enable the stud 2 to be pre-deformed to the large groove 12 side after cooling, appropriate margin is reserved for the subsequent bottoming welding on the small groove 13 side to the deformation on the small groove 13 side, and the deformation of the stud 2 in the whole welding process can be more effectively controlled.
Step three: back chipping on the small groove 13 side, as shown in fig. 3, adjustment 1# stud 5 is in the horizontality, makes the small groove 13 face up, carries out the back chipping to the backing weld of big groove 12 face, polishes after the back chipping and exposes metallic luster, then carries out PT and detects a flaw and ensures that the welding seam root defect is clear away totally and clears away arc lacing wire 3 simultaneously, anticlockwise rotation rolling tire 22, the back chipping that makes the stud 2 that closes on is in the horizontality in proper order, adopt the same mode to accomplish the back chipping of 2 small grooves 13 sides of remaining 6 studs, the back chipping order is: 1# stud 5 → 2# stud 6 → 3# stud 7 → 4# stud 8 → 5# stud 9 → 6# stud 10 → 7# stud 11; in the step, as the root possibly has defects such as air holes, microcracks and the like, the purpose of back chipping is to eliminate the defects which affect the performance of the joint, ensure the internal quality of the root of the welding seam during subsequent welding and improve the flaw detection qualification rate during final inspection of the welding seam.
Step four: backing welding is performed on the small-groove side 13, as shown in fig. 3, the 1# stud 5 is adjusted to be in a horizontal state, the small groove 13 faces upwards, after the welding area of the stud 2 and the central body 1 is preheated to a preset temperature, backing welding is performed on the small groove 13 side by adopting submerged arc welding, the welding deformation is detected and controlled within the range of 2-3 mm by using a sample plate 21, a roller 22 is rotated anticlockwise, the adjacent studs 2 are sequentially in the horizontal state, backing welding on the small groove 13 side of the 2 studs 2 is completed by adopting the same mode, and the welding sequence is as follows: 1# stud 5 → 2# stud 6 → 3# stud 7; in the step, the vertical bar 2 is pre-deformed towards the small groove 13 side after being cooled by adopting a reverse deformation method, a proper margin is reserved for the subsequent filling welding of the large groove 12 side towards the deformation of the large groove 12 side, the requirements on the reverse deformation prefabricated in the stages of backing welding and subsequent filling welding, transition and cover surface welding of the small groove 13 side are stricter, and the deformation of the vertical bar 2 in the whole welding process can be more effectively controlled.
Step five: backing welding on the small groove 13 side and filling welding on the large groove 12 side, as shown in fig. 4 and 5, uniformly distributing stop blocks 14 at positions 50-60 mm away from the groove side edges of the front and back sides of all the studs 2 along the axial direction, finishing backing welding of 3 studs 2 at the moment, when backing welding on the small groove 13 side of the 4# stud 8 is to be carried out, enabling the large groove 12 of the 1# stud 5 to face upwards, considering that the backing welding on the small groove 13 side of the 1# stud 5 can enter a welding line filling stage, rotating a roller 22 anticlockwise, adjusting the 1# stud 5 and the 4# stud 8 to be in an axial symmetry state, arranging a triangular backing plate 15 on the 1# stud 5 and the 4# stud 8 along the axial direction, laying a submerged arc welding trolley 23 and a track 16 on the triangular backing plate 15, preheating the welding areas of the studs 2 and the central body 1 to a preset temperature, and performing backing welding on the small groove 13 of the 4# stud 8 by adopting submerged arc welding on the submerged arc welding side, the welding deformation is detected and controlled within the range of 2-3 mm by using a sample plate 21, the side of a large groove 12 of the 1# stud 5 is subjected to filling welding by adopting submerged arc welding, the welding deformation is detected and controlled within 2mm by using the sample plate 21, bottoming welding of the side of 2 small grooves 13 of the remaining 4 studs and filling welding of the side of the large groove 12 of the 1# studs 5 and the 4# studs 8 are completed in the same mode, and the welding sequence is as follows: the No. 4 stud 8+1# stud 5 → the No. 5 stud 9+2# stud 6 → the No. 6 stud 10+3# stud 7 → the No. 7 stud 11+4# stud 8; in the step, the submerged-arc welding trolleys 23 are adjusted to a horizontal welding station by utilizing the triangular backing plate 16, and the backing welding of the small groove 13 side and the filling welding of the large groove 12 side are simultaneously finished by adopting the two submerged-arc welding trolleys 23, so that the production efficiency is greatly improved.
Step six: filling welding, as shown in fig. 4, rotating the roller 22 counterclockwise to adjust the 1# stud 5 and the 4# stud 8 to be in an axisymmetric state, preheating the to-be-welded areas of the studs 2 and the central body 1 to a predetermined temperature, simultaneously performing filling welding of submerged arc welding on the 1# stud 5 and the 4# stud 8 in the axisymmetric state by using 2 submerged arc welding trolleys 23, detecting and controlling welding deformation within 2mm by using a template 21, rotating the roller 22 counterclockwise to enable adjacent studs 2 to be in the axisymmetric state in sequence, wherein the welding sequence is as follows: 1# stud 5+4# stud 8 → 2# stud 6+5# stud 9 → 3# stud 7+6# stud 10 → 4# stud 8+7# stud 11 → 5# stud 9+1# stud 5 → 6# stud 10+2# stud 6 → 7# stud 11+3# stud 7 until the weld seam is full; the filling welding stage occupies most time of the whole welding work, in the step, the triangular backing plate 15 is used for adjusting the submerged-arc welding trolley 23 to a horizontal welding station, and two submerged-arc welding trolleys 23 are adopted for simultaneously completing filling welding of two vertical bars 2 in an axisymmetric state, so that the production efficiency is greatly improved.
Step seven: transition and capping welding, as shown in fig. 6, adopt 2 vertical bars 2 axisymmetric mode submerged arc welding similarly, detect and control the welding deformation within 2mm with the template 21, rotate the tire 22 counterclockwise, make the adjacent vertical bar 2 in the axisymmetric state sequentially, the welding sequence is: 1# stud 5+4# stud 8 → 2# stud 6+5# stud 9 → 3# stud 7+6# stud 10 → 4# stud 8+7# stud 11 → 5# stud 9+1# stud 5 → 6# stud 10+2# stud 6 → 7# stud 11+3# stud 7 until the weld seam weld fillet is completed, and each welding pass is required to be uniform, the weld fillet meets the drawing requirement, and the undercut is avoided; the function of this step has realized presenting the double-lathe submerged arc welding of axisymmetric stud 2, it is favorable to raising production efficiency, the control in the course of transition and cover welding is very important to guaranteeing appearance quality and weld seam size after welding.
Step eight: performing intersection inspection, performing VT, UT and MT flaw detection on the welding seams after the welding is finished, performing stress relief annealing after the welding seams are qualified, performing VT, UT and MT flaw detection on the welding seams again after the annealing is finished, and turning to a next procedure after the requirements are met; the purpose of stress relief annealing in the step is to eliminate the internal stress of the welded structural part and improve the use safety of the rotor support.
Furthermore, in the first step, the central body 2 and the stud 1 are both made of SM 570-F forgings, and the dummy ring 4 for the rolling tire 22 is made of an SM570 steel plate;
further, the preheating temperature of the back cover welding of the gas shielded welding in the first step and the installation of the false ring 4 is not lower than 100 ℃, the welding wire is phi 1.2mmAWS ER90S-G, the submerged arc backing welding of the large groove 12 in the second step, the submerged arc backing welding of the small groove 13 in the third step, the submerged arc filling welding in the fourth step, the preheating temperature of the submerged arc transition and cover surface stage in the fifth step are not lower than 120 ℃, and the welding wire and the welding flux are respectively phi 4mmAWS F62P4-EA3-A3 and AWS F62P4-EA3-A3 with 10-60 meshes;
further, the welding specification of the gas shielded welding in the step one is as follows: the current is 210-: 78% Ar + 22% CO 2Flow rate: 12-20L/min;
further, the welding specification of the submerged-arc backing welding of the side of the large slope 12 in the second step is as follows: the current is 450A, the voltage is 30V, and the welding speed is 450-550 mm/min; in the step, the submerged-arc backing welding of the side of the large groove 12 is critical, and small-specification welding is generally adopted, so that the welding quality is ensured.
Further, the welding specification of the submerged arc backing welding of the small groove 13 side in the fourth step is as follows: the current is 450-500A, the voltage is 30-31V, and the welding speed is 450 mm/min; in the step, the submerged-arc backing welding at the side of the small groove 13 is more critical, and the welding is generally carried out by adopting smaller specifications, so that the welding quality is favorably ensured.
Further, the welding specifications of the submerged arc filling welding on the side of the large slope 12 in the fifth step and the submerged arc filling welding in the sixth step are as follows: the current is 650A, the voltage is 32V, and the welding speed is 350-400 mm/min; the filling welding in the step adopts large standard for welding, which is beneficial to improving the metal cladding efficiency and improving the production efficiency.
Further, the welding specifications of the submerged arc transition and the cover surface welding in the seventh step are as follows: the current is 600A, the voltage is 31-32V, and the welding speed is 350-; in the step, the submerged arc transition and the cover surface welding are carried out by adopting larger specifications, which is beneficial to improving the metal cladding efficiency and improving the production efficiency.
Further, the welding specification of the last welding pass of the submerged arc transition and the cover surface welding in the seventh step is as follows: the current is 500A, the voltage is 30V, and the welding speed is 500 mm/min; in the step, the last welding of submerged arc transition and cover surface welding adopts small standard rapid welding, which is beneficial to controlling undercut defects.
Further, as shown in fig. 11, the large and small notches of the stud 2 are polygonal transitional notches; in the step, the original K-shaped groove of the stud 2 is changed into a broken line transition-shaped groove, so that the filling amount of the welding wires is reduced, and the production and manufacturing cost is saved.
The present invention is illustrative only and not intended to limit the scope thereof, and those skilled in the art can make modifications to the present invention without departing from the spirit and scope thereof.
Claims (10)
1. A double-vehicle submerged arc welding manufacturing method of a seven-stud rotor bracket is characterized by comprising the following steps of: the method is realized by the following steps:
the method comprises the following steps: root back sealing, after the circumferential weld of the central body (1) is welded, vertically placing the central body (1) and the vertical ribs (2), preheating to-be-welded areas of the central body (1) and the vertical ribs (2), performing back sealing of groove roots by adopting gas shielded welding, welding arc-shaped lacing wires (3) between the lateral plane of small grooves (13) of the vertical ribs (2) and the central body (1), and simultaneously installing dummy rings (4) for rolling tires (22) at two sides of the central body (1);
Step two: big groove (12) side bottoming welding, central body (1) that will adorn welding stud (2) is crouched and is put on rolling child (22), adjustment 1# stud (5) are in the horizontality, make big groove (12) face up, treat welding area with stud (2) and central body (1) and preheat to the predetermined temperature after, adopt submerged arc welding bottoming welding, welding thickness controls according to 30 ~ 40mm, and detect control welding deformation in 3 ~ 5mm within range with model (21), anticlockwise rotation rolling child (22), make adjacent stud (2) be in the horizontality in proper order, adopt the same mode to accomplish the bottoming welding of remaining 6 stud (2) big groove (12) sides, the welding order is: 1# stud (5) → 2# stud (6) → 3# stud (7) → 4# stud (8) → 5# stud (9) → 6# stud (10) → 7# stud (11);
step three: back chipping on minor groove (13) side, adjustment 1# founds muscle (5) and is in the horizontality, make minor groove (13) face up, back chipping is carried out to the backing weld of big slide groove (12) face, polish after the back chipping and expose metallic luster, then carry out PT and detect a flaw and ensure that welding seam root defect clears away totally and clear away arc lacing wire (3) simultaneously, anticlockwise rotation rolling die (22), the founding muscle (2) that make to close on are in the horizontality in proper order, adopt the same mode to accomplish remaining 6 founding muscle (2), the back chipping of minor groove (13) side, the back chipping order is: 1# stud (5) → 2# stud (6) → 3# stud (7) → 4# stud (8) → 5# stud (9) → 6# stud (10) → 7# stud (11);
Step four: welding is made at the end to minor groove (13) side, adjust 1# stud (5) and be in the horizontality, make minor groove (13) face up, treat welding area with stud (2) and centre body (1) and preheat to the predetermined temperature after, adopt submerged arc welding to make the end to minor groove (13) side and weld, detect control welding deformation in 2 ~ 3mm within ranges with model (21), anticlockwise rotation rolls child (22), make the stud (2) that close to be in the horizontality in proper order, adopt the same mode to accomplish and close on the welding at the end of 2 studs (2) minor groove (13) sides, the welding order is: 1# stud (5) → 2# stud (6) → 3# stud (7);
step five: backing welding at the small groove (13) side and filling welding at the large groove (12) side, uniformly distributing stop blocks (14) at positions 50-60 mm away from the groove side edges of the front and back surfaces of all the vertical ribs (2) along the axial direction, finishing backing welding of 3 vertical ribs (2), finishing backing welding at the small groove (13) side of a 1# vertical rib (5) when backing welding at the small groove (13) side of a 4# vertical rib (8) is prepared, enabling the large groove (13) surface of the 1# vertical rib (5) to face upwards, finishing backing welding at the small groove (13) side of the 1# vertical rib (5), enabling the 1# vertical rib (5) to enter a weld filling stage, rotating a rolling tire (22) anticlockwise, adjusting the 1# vertical rib (5) and the 4# vertical rib (8) to be in an axial symmetry state, arranging a triangular backing plate (15) on the 1# vertical rib (5) and the 4# vertical rib (8) along the axial direction, and simultaneously laying a submerged-arc welding trolley (23) and a track (16) on the triangular backing plate (15), preheating to-be-welded areas of a stud (2) and a central body (1) to a preset temperature, backing welding is carried out on the side of a small groove (13) of a 4# stud (8) by adopting submerged arc welding, a sample plate (21) is used for detecting and controlling welding deformation within the range of 2-3 mm, filling welding is carried out on the side of a large groove (12) of a 1# stud (5) by adopting submerged arc welding, the sample plate (21) is used for detecting and controlling welding deformation within 2mm, backing welding on the side of the small groove (13) of the remaining 4 studs (2) and filling welding on the side of the large groove (12) of the 1# studs (5) -4 # studs (8) are completed in the same mode, and the welding sequence is as follows: the number 4 of studs (8) + the number 1 of studs (5) → the number 5 of studs (9) + the number 2 of studs (6) → the number 6 of studs (10) + the number 3 of studs (7) → the number 7 of studs (11) + the number 4 of studs (8);
Step six: filling welding, anticlockwise rotation roll child (22), adjust 1# stud (5) -4 # stud (8) and be in the axisymmetric state, treat welding zone with stud (2) and centerbody (1) and preheat to the predetermined temperature after, adopt 2 submerged arc welding dollies (23) to carrying out the filling welding of submerged arc welding to 1# stud (5) -4 # stud (8) that are the axisymmetric state simultaneously, detect with model (21) and control welding deformation within 2mm, anticlockwise rotation roll child (22), make adjacent stud (2) be in the axisymmetric state in proper order, the welding order is: 1# stud (5) +4# stud (8) → 2# stud (6) +5# stud (9) → 3# stud (7) +6# stud (10) → 4# stud (8) +7# stud (11) → 5# stud (9) +1# stud (5) → 6# stud (10) +2# stud (6) → 7# stud (11) +3# stud (7) until the weld seam is welded to capacity;
step seven: transition and capping welding, adopt 2 vertical bars (2) axisymmetric mode submerged arc welding equally, detect with model (21) and control welding deformation within 2mm, anticlockwise rotation rolls child (22), makes vertical bar (2) that close to be in the axisymmetric state in proper order, and the welding order is: 1# stud (5) +4# stud (8) → 2# stud (6) +5# stud (9) → 3# stud (7) +6# stud (10) → 4# stud (8) +7# stud (11) → 5# stud (9) +1# stud (5) → 6# stud (10) +2# stud (6) → 7# stud (11) +3# stud (7) until weld fillet welding is completed;
Step eight: and (4) cross inspection, performing VT, UT and MT flaw detection on the welding seams after welding is finished, performing stress relief annealing after the welding seams are qualified, performing VT, UT and MT flaw detection on the welding seams again after annealing, and performing acceptance and next sequence after requirements are met.
2. The method for manufacturing the seven-stud rotor bracket by double-vehicle submerged arc welding according to claim 1, wherein the method comprises the following steps: in the first step, the central body (1) and the vertical ribs (2) are both made of SM 570-F forged pieces, and the false ring (4) for the rolling tire (22) is made of an SM570 steel plate.
3. The method for manufacturing the seven-stud rotor bracket by double-vehicle submerged arc welding according to claim 1, wherein the method comprises the following steps: the preheating temperature of the back cover welding and the false ring mounting (4) of the gas shielded welding in the first step is not lower than 100 ℃, the welding wire is phi 1.2mm AWS ER90S-G, the submerged arc backing welding of the large groove (12) in the second step, the submerged arc backing welding of the small groove (13) in the third step, the submerged arc filling welding in the fourth step, and the preheating temperature of the submerged arc transition and cover surface stage in the fifth step are not lower than 120 ℃, and the welding wire and the welding flux are respectively phi 4mm AWS F62P4-EA3-A3 and 10-60 mesh AWS F62P4-EA 3-A3.
4. The method for manufacturing the seven-stud rotor bracket by double-vehicle submerged arc welding according to claim 1, wherein the method comprises the following steps: the welding specification of the gas shielded welding in the step one is as follows: the current is 210-: 78% Ar + 22% CO 2Flow rate: 12-20L/min.
5. The method for manufacturing the seven-stud rotor bracket by double-vehicle submerged arc welding according to claim 1, wherein the method comprises the following steps: the welding specification of the large groove (12) side submerged arc backing welding in the step two is as follows: the current is 450A, the voltage is 30V, and the welding speed is 450-550 mm/min.
6. The method for manufacturing the seven-stud rotor bracket by double-vehicle submerged arc welding according to claim 1, wherein the method comprises the following steps: the welding specification of the submerged-arc backing welding at the side of the small groove (13) in the fourth step is as follows: the current is 450-500A, the voltage is 30-31V, and the welding speed is 450 mm/min.
7. The method for manufacturing the seven-stud rotor bracket by double-vehicle submerged arc welding according to claim 1, wherein the method comprises the following steps: the welding specifications of the submerged arc filling welding at the side of the large groove (12) in the fifth step and the submerged arc filling welding in the sixth step are as follows: the current 650A, the voltage 32V and the welding speed 350-.
8. The method for manufacturing the seven-stud rotor bracket by double-vehicle submerged arc welding according to claim 1, wherein the method comprises the following steps: welding specifications of submerged arc transition and cover surface welding in the seventh step are as follows: the current is 600A, the voltage is 31-32V, and the welding speed is 350-.
9. The method for manufacturing the seven-stud rotor bracket by double-vehicle submerged arc welding according to claim 1, wherein the method comprises the following steps: the welding specification of the last submerged arc transition and cover surface welding in the seventh step is as follows: the current is 500A, the voltage is 30V, and the welding speed is 500 mm/min.
10. The method for manufacturing the seven-stud rotor bracket by double-vehicle submerged arc welding according to claim 1, wherein the method comprises the following steps: the large and small groove forms of the vertical ribs (2) are fold line transition grooves.
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