CN114799410A - Forming process of ultra-large marine flange - Google Patents
Forming process of ultra-large marine flange Download PDFInfo
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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
- B23K9/013—Arc cutting, gouging, scarfing or desurfacing
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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
- B23K9/16—Arc welding or cutting making use of shielding gas
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
Abstract
The invention relates to a forming process of an ultra-large marine flange, which adopts sectional blanking and sectional assembly to form the ultra-large marine flange by tailor-welding, reduces the welding deformation amount by a welding deformation prevention tool in the welding process, and releases welding stress by a post-treatment process subsequently to ensure that the tailor-welded and formed ultra-large marine flange meets the requirements of a design drawing. Therefore, on one hand, the requirements on processing conditions can be effectively reduced, and large-size blanking steel plates, large-processing-capacity blanking cutting equipment and large blanking fields are not required to be matched for manufacturing the ultra-large marine flange; on the other hand, the turning-over operation of the ultra-large marine flange is not required in the whole welding process, so that the time and the labor are saved; on the other hand, through strict process control in manufacturing and forming, the formed ultra-large marine flange can be effectively ensured to have good dimensional precision and shape precision, and subsequent machining and assembling work can be smoothly carried out.
Description
Technical Field
The invention relates to the technical field of flange welding forming, in particular to a forming process of an ultra-large marine flange.
Background
A3200T self-elevating wind power installation ship of European shipowner company born by the middle and far marine transportation group is specially designed for integration of transportation, lifting and installation of offshore wind power generation sets, connecting pieces and bases. Unlike conventional self-elevating wind power installation vessels, the vessel is more flexible to maneuver. Besides being capable of loading various types of offshore wind turbine generators and bases, the ship type can also improve the offshore installation operation efficiency of a smooth deck with a larger area, and simultaneously reduces the energy consumption and the greenhouse gas emission. The ship not only provides equipment support for sustainable development of marine green clean energy industry, but also can be used for dismantling and transporting marine structures.
A pile-winding crane with lifting capacity of 3200 tons is arranged at the stern of the 3200T self-elevating wind power installation ship, and a smooth operation deck is arranged at the midship. This vessel has four truss legs and operates at water depths in excess of 80 meters and is equipped with a DP2 dynamic positioning system that provides stable operating conditions under complex sea conditions. The ultra-large marine flange matched with the pile winding crane is annular as a whole, the outer diameter of the ultra-large marine flange exceeds 20m, the radial thickness of the ultra-large marine flange exceeds 450mm, and the total weight of the ultra-large marine flange exceeds 56T. In the initial stage of project development, through a large number of published documents at home and abroad, it is known that the marine flange is usually manufactured by cutting and blanking by using a gantry cutting machine at the initial stage, and then forming is carried out by machining, cutting and grinding, however, the maximum size of the formed marine flange is not more than 4 m. The forming process can not meet the manufacturing requirement of the flange for the ultra-large ship with the outer diameter of more than 20 m. In addition, according to published data, a shipbuilding factory in the same industry abroad develops a segmented blanking and segmented assembly tailor-welding process for ultra-large marine flanges (published reports, a shipbuilding factory in Korea adopts a segmented tailor-welding process to manufacture and mold marine flanges with the diameter of more than 15 m), however, the shipbuilding factory lacks an effective welding deformation control means, has a large welding deformation amount in a specific implementation process, and needs to perform shape correction by subsequently spending a large amount of manpower and material resources; the welded residual stress of the welded flange is large, so that the secondary deformation of the ultra-large marine flange is caused due to stress release in the later processing stage, the subsequent machining difficulty is large, and the control of the final machining precision is not facilitated. In addition, in order to ensure that the welding gun can smoothly reach the welding area, the flange for the welding ship needs to be frequently turned over in the welding process, which is time-consuming and labor-consuming, and is easily deformed due to the lifting force, so that technical personnel are urgently needed to solve the problems.
Disclosure of Invention
Therefore, in view of the above-mentioned problems and drawbacks, the present invention provides a method for forming a flange for a very large ship, which comprises collecting relevant data, evaluating and considering the data, and performing experiments and modifications by a skilled person engaged in the industry.
In order to solve the technical problem, the invention relates to a forming process of an ultra-large marine flange, the ultra-large marine flange is made of ASTM A694, the outer diameter R is more than 20m, the radial width W is more than 450mm, the thickness T is more than 200mm, the ultra-large marine flange is formed by welding N equal-length arc-shaped flange sections in a splicing manner, and the forming process comprises the following steps:
s1, a lofting and nesting stage, which comprises the following substeps:
s11, carrying out equal-division lofting on the ultra-large ship flange according to a design blueprint of the ultra-large ship flange, and cutting to form N initial arc-shaped flange sections with completely consistent specifications;
s12, forming tailor welded joint grooves at two ends of the initial arc-shaped flange section to form a prewelded arc-shaped flange section;
s2, scribing and assembling the stage, wherein the scribing and assembling stage comprises the following substeps:
s21, marking on a welding platform according to a blueprint of the flange design for the ultra-large ship to be used as a positioning reference of each pre-welded arc-shaped flange section; the welding platform is preferably formed by circumferentially arranging N parts of jig frames;
s22, placing the pre-welded arc-shaped flange sections on a welding platform, adjusting the relative positions and postures of the pre-welded arc-shaped flange sections by taking the marking as reference, and incidentally forming welding seams which are kept in a suspended state relative to the jig frame between the adjacent pre-welded arc-shaped flange sections;
s3, formally welding preparation working phase, reducing the welding deformation amount of the pre-welded arc-shaped flange section by means of the welding deformation prevention tool:
s4, in the welding stage, welding seams are filled in a welding mode, and the ultra-large marine flange is formed in a welding mode;
and S5, post-processing, and eliminating post-welding stress of the ultra-large marine flange.
As a further improvement of the technical proposal of the invention, in step S11, N is more than or equal to 8.
As a further improvement of the technical scheme of the invention, in step S12, the tailor-welded seam groove is preferably a 55-65 degree X-shaped groove, and the middle part of the tailor-welded seam groove is reserved with 2-4 mm.
As a further improvement of the technical scheme of the invention, in step S4, when the arc-shaped flange section is pre-welded, the welding operation is performed, the heating and temperature rising treatment is performed within 75mm of the two sides of the pre-welding area, and the interlayer temperature is controlled to be 150-250 ℃. And after welding, covering aluminum silicate cotton on the formed welding line for slow cooling.
As a further improvement of the technical scheme of the invention, in step S3, the welding deformation preventing tool is composed of N/2 supporting section bar sections. The supporting section bar sections are horizontally arranged right above the welding platform and are mutually staggered, and the two end parts of the supporting section bar sections are respectively spot-welded on the two symmetrical pre-welded arc-shaped flange sections.
As a further improvement of the technical solution of the present invention, step S5 includes the following substeps:
s51, after the ultra-large ship flange is welded and formed, removing the supporting section until the supporting section is completely separated from the welding platform and the ultra-large ship flange;
and S52, performing a vibration aging treatment process on the completely free state ultra-large ship flange.
As a further improvement of the technical scheme of the invention, in step S52, Q excitation points are arranged around the flange of the ultra-large ship, and Q is more than or equal to 4. And the vibration aging adopts a mode of vibration in a grading mode, and vibration exciting loads for 45-60 min are sequentially applied to the vibration exciting points.
Of course, as another modified design of the above technical solution, in step S3, the welding deformation preventing tool is composed of an external limiting unit and an internal limiting unit. The external limiting unit is composed of M-N external limiting plates which are welded on the welding platform and evenly distributed in equal intervals for radially limiting the outer side wall of the pre-welded arc-shaped flange section. The built-in limiting unit is composed of M-N built-in limiting plates welded on the welding platform and used for radially limiting the inner side wall of the pre-welded arc-shaped flange section in an equally-distributed mode. N is more than or equal to 2.
As a further improvement of the technical solution of the present invention, step S5 includes the following substeps:
s51', after the ultra-large marine flange is welded and molded, removing both the external limiting plate and the internal limiting plate on the welding platform;
s52', the vibration aging treatment process is carried out on the flange of the completely free state ultra-large ship.
As a further improvement of the technical scheme of the invention, compared with the vibration aging treatment process in the step S52, in the step S52', P vibration excitation points are arranged around the flange of the ultra-large ship, and P is more than or equal to 4. And the vibration aging adopts a mode of vibration in a grading mode, and vibration exciting loads for 45-60 min are sequentially applied to the vibration exciting points.
Of course, as another modified design of the above technical solution, step S5 includes the following sub-steps:
s51', and manufacturing an annular heating cover matched with the shape of the flange for the ultra-large ship. The annular heating cover is composed of a cover body and a heating unit. The cover body and the welding platform can form a closed cavity for accommodating the ultra-large marine flange. The heating unit is composed of an electric heating unit and a power supply. The electric heating unit comprises at least one electric heating wire which is fixed on the inner side wall of the cover body and inputs heat towards the closed cavity. The power supply provides electric support for the heating wires;
s52', placing the cover body on a welding platform, and carrying out closed cover on the ultra-large ship flange and the welding deformation prevention tool at the same time;
s53', starting the power supply, enabling the heating wire to release heat to the closed cavity until the temperature of the closed cavity reaches 520-550 ℃, controlling the temperature rise speed to be below 120 ℃/h, and keeping the temperature for not less than 3.5 h;
s54', turning off the power supply and keeping the ultra-large marine flange in a natural slow cooling environment;
s55', planing off both the external limiting plate and the internal limiting plate on the welding platform to remove the limitation on the ultra-large marine flange.
As a further improvement of the technical scheme of the invention, the forming process of the ultra-large marine flange further comprises a step S52a ' which is arranged between the step S52 ' and the step S53 '. In step S52a ″, an inert gas is injected into the sealed cavity.
As a further improvement of the technical solution of the present invention, in step S53 ″, when the temperature of the sealed cavity is controlled to be 520 to 540 ℃, the inert gas is preferably helium; when the temperature of the sealed cavity is controlled to be 540-550 ℃, the inert gas is preferably a hydrogen-helium mixed gas containing 2-10% of hydrogen.
According to the technical scheme disclosed by the invention, the ultra-large marine flange is formed by adopting sectional blanking and sectional assembly in a tailor-welding mode, the welding deformation amount is reduced by the welding deformation prevention tool in the welding process, and the welding stress is released by a post-treatment process subsequently, so that the tailor-welded ultra-large marine flange can meet the requirement of a design drawing. Therefore, on one hand, the requirements on processing conditions are effectively reduced, and large-size blanking steel plates, large-processing-capacity blanking cutting equipment and a large blanking field are not required to be matched for manufacturing the ultra-large marine flange, so that the manufacturing difficulty and the cost of the ultra-large marine flange are greatly reduced; on the other hand, the turning-over operation of the ultra-large marine flange is not required in the whole welding process, so that the time and the labor are saved; on one hand, the formed ultra-large marine flange is effectively ensured to have good dimensional precision and shape precision through strict process control in manufacturing and forming, and subsequent machining and assembling work is favorably and smoothly carried out.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic view of the construction of one of the initial arcuate flange segments of the ultra-large marine flange of the present invention.
FIG. 2 is a schematic layout diagram of the ultra-large marine flange on a welding platform after the ultra-large marine flange is assembled in sections and before the welding operation is performed formally.
Fig. 3 is a schematic diagram illustrating the first embodiment of the forming process of the ultra-large marine flange according to the present invention.
Fig. 4 is a schematic diagram of the second embodiment of the forming process of the ultra-large marine flange.
Fig. 5 is a schematic diagram illustrating the third embodiment of the forming process of the ultra-large type marine flange according to the present invention.
FIG. 6 is a schematic diagram of the welding procedure for applying the welding seam on the flange of the ultra-large ship.
FIG. 7 shows the welding procedure for applying the welding seam on the ultra-large marine flange according to the invention.
1-ultra large marine flange; 11-a first arcuate flange section; 12-a second arcuate flange section; 13-a third arcuate flange section; 14-a fourth arcuate flange section; 15-a fifth arcuate flange section; 16-a sixth arcuate flange section; 17-a seventh arcuate flange section; 18-an eighth arcuate flange section; 2-welding a platform; 21-a first jig frame; 22-a second jig; 23-a third jig; 24-a fourth jig; 25-a fifth jig; 26-a sixth jig; 27-a seventh jig; 28-eighth jig; 3-welding deformation prevention tooling; 31-a first support profile section; 32-a second support profile section; 33-a third support profile section; 34-a fourth support profile section; 35-external limiting unit; 36-built-in limiting unit; 4-excitation generating unit; 41-a first vibration exciter; 42-a second exciter; 43-a third exciter; 44-a fourth exciter; 5-annular heating cover; 51-a cover; 52-a heating unit; 521-an electric heating unit; 5211 heating wire.
Detailed Description
The ultra-large marine flange disclosed by the invention is applied to a 3200T self-elevating type wind power installation vessel to be used as a rotary support member for performing hoisting operation. The specific parameters of the ultra-large marine flange are as follows: the material is ASTM A694 (-40 ℃ CVN), the outer diameter R is greater than 20m, the radial width W is greater than 450mm, and the thickness T is greater than 200mm (as shown in FIG. 2).
The following detailed description is made for the disclosed matter in connection with specific embodiments, and the subject matter is: the ultra-large marine flange is formed by assembling and welding 8 equal-length arc-shaped flange sections. The forming process of the ultra-large marine flange comprises the following steps:
s1, a lofting and nesting stage, which comprises the following substeps:
s11, equally dividing and lofting the ultra-large marine flange 1 according to the design blueprint thereof, and performing a cutting operation to form 8 initial arc-shaped flange sections (as shown in fig. 1) with completely consistent specifications;
s12, forming tailor welded joint grooves at two ends of each initial arc-shaped flange section to form prewelded arc-shaped flange sections; and for the following convenience and pertinence, the arc-shaped flange sections are named as a first arc-shaped flange section 11, a second arc-shaped flange section 12, a third arc-shaped flange section 13, a fourth arc-shaped flange section 14, a fifth arc-shaped flange section 15, a sixth arc-shaped flange section 16, a seventh arc-shaped flange section 17 and an eighth arc-shaped flange section 18 respectively along the direction of the counter-potential needle;
s2, scribing and assembling the stage, wherein the scribing and assembling stage comprises the following substeps:
s21, marking on the welding platform 2 according to the design blueprint of the ultra-large marine flange 1 to be used as a positioning reference of each pre-welded arc-shaped flange section;
s22, placing the pre-welded arc-shaped flange sections on the welding platform 2, adjusting the relative positions and postures of the pre-welded arc-shaped flange sections by taking the scribing line as a reference, and incidentally forming welding lines between the adjacent pre-welded arc-shaped flange sections;
s3, in the formal welding preparation working stage, reducing the welding deformation of the pre-welded arc-shaped flange section by the welding deformation preventing tool 3:
s4, in the welding stage, welding seams are filled in a welding mode, and the ultra-large marine flange is formed in a welding mode;
and S5, post-processing, and eliminating the post-welding stress of the ultra-large marine flange 1.
The forming process adopts the sectional blanking and the sectional assembly mode to form the ultra-large marine flange 1 by tailor welding, the welding deformation amount is reduced by the welding deformation prevention tool 3 in the welding process, and the welding stress is released by the post-treatment process subsequently, so that the tailor welded and formed ultra-large marine flange can meet the requirement of a design drawing.
In practical implementation, the forming process of the ultra-large marine flange has the following beneficial effects:
1) the requirements on processing conditions are effectively reduced, and a large-size blanking steel plate, large-processing-capacity blanking cutting equipment and a large blanking field are not required to be matched for manufacturing the ultra-large marine flange 1, so that the manufacturing difficulty and the cost of the ultra-large marine flange are greatly reduced;
2) through strict process control in manufacturing and forming, the formed ultra-large marine flange 1 is effectively ensured to have good dimensional accuracy and shape accuracy, and subsequent machining and assembling work is favorably and smoothly carried out.
Here, in order to avoid the need to frequently perform the turning operation on the flange 1 for the very large vessel in performing the welding operation, the welding platform 8 is preferably composed of 8 first, second, third, fourth, fifth, sixth, seventh, and eighth jigs 21, 22, 23, 24, 25, 26, 27, and 28 arranged in this order in a counterclockwise direction. When each pre-welding arc-shaped flange section is placed relative to the corresponding jig frame and is positioned, the welding seam is kept in a suspended state relative to the jig frame.
On the premise of ensuring a good welding seam, in order to reduce the filling amount of the molten pool as much as possible and further reduce the welding deformation of the ultra-large marine flange 1, in step S12, the tailor welded seam groove is preferably a 55-65 ° X-shaped groove with a root 2-4 mm (as shown in fig. 6) in the middle. The specific welding steps are as follows: the welding seam adopts multilayer multi-channel and front and back alternate welding mode, welding parameters such as welding material selection, protective gas selection, preheating temperature and welding current and voltage are strictly executed according to the corresponding WPS (welding process specification) (as shown in figure 7), and the specific steps are as follows:
step one, 4 high-quality welders with (3G + 4G) quality are used for welding at the same time. As shown in fig. 2, in the welding process, the overall 8-seam welding sequence:
1) firstly welding a welding seam of a cross symmetrical B1 groove;
2) and welding the welding seam with the cross-shaped symmetrical B2 groove.
Step two, the welding sequence of each opening welding seam needs to be executed by referring to the attached figure 6:
1) welding of the first welding B1 ((r →)):
a, filling the mixture to a depth of 35-40mm, then grinding the mixture into MT after carbon gouging back gouging (with certain temperature and no cold carbon) is carried out;
the filling depth is 35-40 mm; firstly, the requirement of the thickness of a welding seam reaches 70-80mm (slightly accurate, convenient for flaw detection), and UT/MT is applied;
2) welding of the second welding B2 ((r →)):
a, filling the mixture to a depth of 35-40mm, then grinding the mixture into MT after carbon gouging back gouging (with certain temperature and no cold carbon) is carried out;
the filling depth is 35-40 mm; firstly, the requirement of the thickness of a welding seam reaches 70-80mm (slightly accurate, convenient for flaw detection), and UT/MT is applied;
3) welding of a third step B1 ((c → h)):
the filling depth is 35-40mm → the filling depth is 35-40 mm; fourthly, the requirement of the thickness of the welding line reaches 140-160mm (slightly accurate, convenient for flaw detection), and UT/MT is applied;
4) welding in the fourth step B2 ((c → h)):
the filling depth is 35-40mm → the filling depth is 35-40 mm; fourthly, the requirement of the thickness of the welding line reaches 140-160mm (slightly accurate, convenient for flaw detection), and UT/MT is applied;
5) fifthly, welding B1 (fifth step → sixth step → seventh step → final UT/MT flaw detection
6) Sixth step welding B2 (C → G → final UT/MT flaw detection)
Note: a: the temperature of UT/MT flaw detection welding line is less than 50 ℃; and b, the welding sequence is only in guide, and the actual situation needs to be adjusted in time according to the data (the planeness, the diameter, the radius and the welding seam shrinkage) of the actual field monitoring.
Before performing the welding operation of the welding seams of the needles B1 and B2, a welder needs to perform a heating temperature raising process within a range of 75mm on both sides of the pre-welding area by using a baking gun, and the interlayer temperature is controlled to be 150-250 ℃. And after welding, covering aluminum silicate cotton on the formed welding line for slow cooling. Practical experiments verify that the application of the pre-welding preheating and post-welding slow cooling measures has the following two beneficial effects:
1) the method is favorable for the escape of the diffused hydrogen in the weld metal and avoids the generation of hydrogen-induced cracks in the ultra-large marine flange 1. Simultaneously, the hardening degree of the welding seam and the heat affected zone is reduced, and the crack resistance of the formed welding seam is improved;
2) the uniform local preheating or the integral preheating can reduce the temperature difference (also called as temperature gradient) of each layer of the welded ultra-large marine flange 1 in the welding area, thus being beneficial to reducing the welding stress, remarkably reducing the welding strain rate and avoiding the generation of welding cracks.
According to the common sense of design, the welding deformation prevention tool can adopt various design forms to reliably fix each pre-welded arc-shaped flange section on the welding platform 2 so as to prevent the occurrence of position change phenomenon caused by thermal stress or external force action in the welding process, however, an embodiment which has a simple design structure, is easy to implement, is easy to perform dismantling operation in the later period and has excellent practical application effect is recommended here, and the embodiment is specifically as follows: fig. 3 shows an implementation schematic diagram of a first embodiment of the forming process of the ultra-large marine flange according to the present invention, and it can be seen that, in step S3, the welding deformation preventing tool 3 is preferably composed of 4 first support profile segments 31, second support profile segments 32, third support profile segments 33 and fourth support profile segments 34. The first supporting section bar segment 31, the second supporting section bar segment 32, the third supporting section bar segment 33 and the fourth supporting section bar segment 34 are all horizontally arranged right above the welding platform 2 and are arranged in a staggered way, and two end parts of the first supporting section bar segment, the second supporting section bar segment, the third supporting section bar segment and the fourth supporting section bar segment are respectively spot-welded on two symmetrical pre-welded arc-shaped flange segments. The method specifically comprises the following steps: as shown in fig. 3, the two ends of the first support profile section 31 bear against between the first curved flange section 11 and the fifth curved flange section 15; the two ends of the second supporting profile section 32 bear against the space between the fourth curved flange section 14 and the eighth curved flange section 18; the two ends of the third supporting section bar section 33 are propped against the space between the third arc-shaped flange section 13 and the seventh arc-shaped flange section 17; the fourth support profile section 34 bears with its two ends against the second curved flange section 12 and the sixth curved flange section 16. In this way, in the process of performing the welding operation by four welders, the first support profile section 31, the second support profile section 32, the third support profile section 33 and the fourth support profile section 34 always apply a push-pull force to the first arc-shaped flange section 11, the second arc-shaped flange section 12, the third arc-shaped flange section 13, the fourth arc-shaped flange section 14, the fifth arc-shaped flange section 15, the sixth arc-shaped flange section 16, the seventh arc-shaped flange section 17 and the eighth arc-shaped flange section 18, so as to effectively counteract the thermal stress generated in the welding process, thereby making a good cushion for reducing the welding thermal deformation of the flange 1 for the very large ship.
In order to eliminate the residual stress after welding and to make good bedding for subsequent machining and assembling operations, when the first support profile section 31, the second support profile section 32, the third support profile section 33, and the fourth support profile section 34 are planed and completely separated from the welding platform and the ultra-large marine flange, the vibration aging treatment process is performed on the welded and formed ultra-large marine flange 1. Preferably, 4 excitation points are provided around the very large vessel flange 1. The vibration aging adopts a mode of vibration in a grading mode, and vibration exciting loads of 45-60 min duration are applied to the vibration exciting points in sequence. The working principle of vibration aging is roughly as follows: the gear (dynamic stress) of a vibration exciter is determined by the manual function of a VSR-50 type vibration aging instrument, the vibration motor is controlled to accelerate by the full-intelligent automatic function, when the revolution (frequency) of the motor is approximately equal to the natural frequency of the ultra-large type ship flange 1, the ultra-large type ship flange 1 can resonate integrally, and when the dynamic stress applied to the ultra-large type ship flange 1 by the vibration motor is greater than or equal to the yield limit of a material, the residual stress of the ultra-large type ship flange 1 can be released to a certain degree. During vibration, a proper eccentric amount (gear) is selected for the eccentricity of the vibration motor, the motor is controlled to rotate by the controller, when overall resonance occurs, the ultra-large marine flange 1 is in a resonance state, residual stress in the ultra-large marine flange 1 can be released after vibration treatment for a period of time, and residual stress of the rest part of the ultra-large marine flange 1 after vibration is smaller than the yield limit of a material, so that the deformation resistance of the ultra-large marine flange is improved to a certain degree.
Although the first embodiment can stably and reliably fix each pre-welded arc-shaped flange section on the welding platform 2, the position of the very individual pre-welded arc-shaped flange section is changed due to the action of large welding thermal stress, which causes great inconvenience for subsequent normal tests, and the reason is that: either the first support profile section 31 or the second support profile section 32, the third support profile section 33 and the fourth support profile section 34 are cut from a profile (round pipe, angle iron or channel steel, etc.), and particularly in the case of a large length dimension, the structural stability is extremely poor. In contrast, the outer diameter of the ultra-large marine flange 1 according to this embodiment exceeds 20m, and therefore, when the first support profile section 31, the second support profile section 32, the third support profile section 33, and the fourth support profile section 34 are subjected to the end extrusion force, the structural instability phenomenon is easily caused due to bending, and the reliability of the position limitation of each pre-welded arc-shaped flange section is further affected, so that fig. 4 shows an implementation schematic diagram of a second embodiment of the forming process of the ultra-large marine flange according to the present invention, which is different from the first embodiment in that: in step S3, the welding deformation preventing tool 3 is composed of the external stopper unit 35 and the internal stopper unit 36. Wherein, external spacing unit 35 is by 34 external limiting plates that execute welding on welding platform 2, and equally divide the outside wall to preweld arc flange section evenly and carry out radial spacing. The built-in limiting unit 36 is composed of 24 built-in limiting plates welded on the welding platform 2 and equally and uniformly limiting the inner side wall of the pre-welded arc-shaped flange section in the radial direction. For the external limiting unit 35, the reliability of limiting the position of the corresponding pre-welded arc-shaped flange section is only related to the structural strength of the external limiting plate and the welding platform 2, so that the reliable limitation of the relative position of the pre-welded arc-shaped flange section is ensured by the cooperation of the internal limiting unit 36, and the subsequent position change phenomenon caused by the output of welding heat is avoided.
It should be noted again that, after the ultra-large marine flange 1 is welded and molded, and after the external limiting plate and the internal limiting plate are both planed off on the welding platform 2, the vibration aging treatment process is also required to be performed on the ultra-large marine flange 1 in a completely free state, and 4 excitation points are also arranged around the ultra-large marine flange 1. Applying an excitation load for 45-60 min to the excitation point in sequence by adopting a mode of vibration in a fractional manner;
fig. 5 is a schematic diagram illustrating an implementation of a third embodiment of the forming process of the ultra-large marine flange according to the present invention, which is different from the second embodiment in that: the annealing process is adopted to eliminate the stress after welding, and the specific implementation steps are as follows:
1) before the post heat treatment is performed on the flange 1 for the very large ship, the following preparation work is required: and manufacturing an annular heating cover 5 matched with the shape of the ultra-large marine flange 2. The annular heating jacket 5 is constituted by a jacket body 51 and a heating unit 52. The cover 51 in cooperation with the welding platform 2 may form a closed cavity for receiving the very large marine flange 1. The heating unit 52 is composed of an electric heating unit 521 and a power supply 522 (not shown in the figure). The electric heating unit 521 includes a heating wire 5211 fixed to an inner sidewall of the cover 51 to input heat to the closed cavity. The power supply 522 provides electrical support for the heating wire 5211;
2) the annular heating cover 5 is integrally placed on the welding platform 2, and the ultra-large marine flange 1 and the welding deformation prevention tool are simultaneously sealed and covered; note: a heat-preservation cotton sliver is wound at gaps among the first jig frame 21, the second jig frame 22, the third jig frame 23, the fourth jig frame 24, the fifth jig frame 25, the sixth jig frame 26, the seventh jig frame 27 and the eighth jig frame 28 so as to seal a gap of the cover body 51 and avoid the heat dissipation phenomenon in the annular heating cover 5 to the maximum extent;
3) starting a power supply, wherein the heating wire releases heat to the closed cavity until the temperature of the closed cavity reaches 520-550 ℃, the temperature rising speed is controlled to be below 120 ℃/h, and the heat preservation time is not less than 3.5 h;
4) turning off a power supply, and keeping the ultra-large marine flange 1 in a natural slow cooling environment;
5) and finally, removing the external limiting plate and the internal limiting plate from the welding platform 2 to remove the limitation on the ultra-large marine flange 1.
By adopting the technical scheme, on one hand, the heat stress generated by welding can be effectively eliminated, the tissues of the welding seam and the heat affected zone are uniform, the crystal grains of the welding seam and the heat affected zone are refined, and the hydrogen embrittlement generated by the welding seam in the welding process is eliminated; on the other hand, the welding seam metal and the base metal can be better fused through annealing treatment, and the overall structural strength of the ultra-large marine flange 1 can be improved.
In order to avoid the oxide layer from being generated on the surface of the ultra-large marine flange 1 due to the oxidation effect in the annealing treatment and further eliminate the workload of removing the subsequent oxide layer, inert gas can be injected into the closed cavity in the process of performing the temperature rise annealing on the ultra-large marine flange 1.
Finally, it should be noted that, in the annealing process, the carburizing phenomenon of the ultra-large marine flange 1 needs to be strictly prevented to avoid the phenomenon that the internal metallographic structure of the flange is changed to reduce the structural strength of the flange, and in view of the above technical solution, when the temperature of the closed cavity is controlled to be 520 to 540 ℃, the inert gas is preferably helium; when the temperature of the sealed cavity is controlled to be 540-550 ℃, the inert gas is preferably a hydrogen-helium mixed gas containing 2-10% of hydrogen. Either helium or a mixture of hydrogen and helium can effectively reduce the adverse effect of nitrogen gas remained in the sealed cavity on the annealing process.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (13)
1. The forming process of the ultra-large marine flange is characterized by comprising the following steps of:
s1, a lofting and nesting stage, which comprises the following substeps:
s11, equally dividing and lofting the ultra-large marine flange according to the design blueprint of the ultra-large marine flange, and performing cutting operation to form N initial arc-shaped flange sections with completely consistent specifications;
s12, forming tailor welded joint grooves at two ends of the initial arc-shaped flange section to form a prewelded arc-shaped flange section;
s2, scribing and assembling the stage, wherein the scribing and assembling stage comprises the following substeps:
s21, marking on a welding platform according to the ultra-large marine flange design blueprint to be used as a positioning reference of each pre-welded arc-shaped flange section; the welding platform is formed by circumferentially arranging N pieces of jig frames;
s22, placing each pre-welding arc-shaped flange section on the welding platform, adjusting the relative position and posture of the pre-welding arc-shaped flange sections by taking the scribing line as a reference, and incidentally forming a welding seam which is kept in a suspended state relative to the jig frame between the adjacent pre-welding arc-shaped flange sections;
s3, in the formal welding preparation working stage, reducing the welding deformation of the pre-welded arc-shaped flange section by means of a welding deformation prevention tool:
s4, in the welding stage, filling the welding seam by adopting a welding mode, and welding and forming the ultra-large ship flange;
and S5, post-processing, and eliminating the post-welding stress of the ultra-large marine flange.
2. The process for forming a very large marine flange according to claim 1, wherein N.gtoreq.8 in step S11.
3. The forming process of the ultra-large marine flange according to claim 1, wherein in the step S12, the tailor welded seam bevel is a 55-65 ° X-shaped bevel, and the root of the tailor welded seam is 2-4 mm.
4. The forming process of the ultra-large marine flange according to claim 1, wherein in step S4, when the pre-welded arc-shaped flange section is subjected to welding operation, the pre-welded arc-shaped flange section is subjected to heating treatment within a range of 75mm on both sides of a pre-welding area, and the interlayer temperature is controlled to be 150-250 ℃; and after welding, covering aluminum silicate cotton on the formed welding line for slow cooling.
5. The forming process of the ultra-large marine flange according to claim 1, wherein in step S3, the welding deformation preventing tool is composed of N/2 supporting profile sections; the supporting section bar sections are horizontally arranged right above the welding platform and are mutually staggered, and two end parts of the supporting section bar sections are respectively spot-welded on the two symmetrical pre-welded arc-shaped flange sections.
6. The forming process of the ultra-large type marine flange according to claim 5, wherein the step S5 comprises the following substeps:
s51, after the ultra-large ship flange is welded and formed, removing the supporting section until the supporting section is completely separated from the welding platform and the ultra-large ship flange;
and S52, performing a vibration aging treatment process on the ultra-large ship flange in the completely free state.
7. The forming process of the ultra-large marine flange according to claim 6, wherein in step S52, Q excitation points are arranged around the ultra-large marine flange, and Q is more than or equal to 4; and applying the excitation load for 45-60 min to the excitation point in sequence by adopting a mode of vibration in a fractional manner.
8. The forming process of the ultra-large marine flange according to claim 1, wherein in step S3, the welding deformation preventing tool is composed of an external limiting unit and an internal limiting unit; the external limiting units are formed by M-N external limiting plates which are welded on the welding platform and equally and uniformly limit the outer side wall of the pre-welded arc-shaped flange section in the radial direction; the built-in limiting units are formed by M-N built-in limiting plates which are welded on the welding platform and evenly divide and radially limit the inner side wall of the pre-welded arc-shaped flange section; n is more than or equal to 2.
9. The forming process of the ultra-large type marine flange according to claim 8, wherein the step S5 comprises the following substeps:
s51', after the ultra-large ship flange is welded and molded, removing both the external limiting plate and the internal limiting plate on the welding platform;
s52', performing a vibration aging treatment process on the ultra-large ship flange in the completely free state.
10. The forming process of the ultra-large marine flange according to claim 9, wherein in step S52', P excitation points are provided around the ultra-large marine flange, where P is greater than or equal to 4; and applying the excitation load for 45-60 min to the excitation point in sequence by adopting a mode of vibration in a fractional manner.
11. The forming process of the ultra-large type marine flange according to claim 8, wherein the step S5 comprises the following substeps:
s51', manufacturing an annular heating cover matched with the shape of the ultra-large marine flange; the annular heating cover consists of a cover body and a heating unit; the cover body and the welding platform can form a closed cavity for accommodating the ultra-large marine flange; the heating unit consists of an electric heating unit and a power supply; the electric heating unit comprises at least one electric heating wire which is fixed on the inner side wall of the cover body and inputs heat to the closed cavity; the power supply provides electric support for the heating wire;
s52', placing the cover body on the welding platform, and carrying out closed cover on the ultra-large marine flange and the welding deformation prevention tool at the same time;
s53', starting the power supply, wherein the heating wire releases heat to the closed cavity until the temperature of the closed cavity reaches 520-550 ℃, the temperature rising speed is controlled to be below 120 ℃/h, and the heat preservation time is not less than 3.5 h;
s54', turning off the power supply and keeping the ultra-large marine flange in a natural slow cooling environment;
and S55', removing the external limiting plate and the internal limiting plate from the welding platform to remove the limitation on the ultra-large ship flange.
12. The process for forming a very large marine flange according to claim 11, further comprising step S52a "between step S52" and step S53 "; in step S52a ″, an inert gas is injected into the sealed cavity.
13. The forming process of the ultra-large marine flange according to claim 12, wherein in the step S53 ″, when the temperature of the closed cavity is controlled to be 520 to 540 ℃, the inert gas is helium; when the temperature of the closed cavity is controlled to be 540-550 ℃, the inert gas is a hydrogen-helium mixed gas containing 2-10% of hydrogen.
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| CN117840590A (en) * | 2024-03-07 | 2024-04-09 | 成都天成电科科技有限公司 | Method for protecting inner cavity chip during laser re-welding and laser re-welding system |
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