CN115430887A - Full penetration welding method for 16mmU rib with hot-rolled variable cross section of extra-large bridge - Google Patents
Full penetration welding method for 16mmU rib with hot-rolled variable cross section of extra-large bridge Download PDFInfo
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- CN115430887A CN115430887A CN202110622659.0A CN202110622659A CN115430887A CN 115430887 A CN115430887 A CN 115430887A CN 202110622659 A CN202110622659 A CN 202110622659A CN 115430887 A CN115430887 A CN 115430887A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/0026—Arc welding or cutting specially adapted for particular articles or work
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
-
- 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
-
- 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
-
- 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
- B23K9/24—Features related to electrodes
- B23K9/28—Supporting devices for electrodes
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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 full penetration welding method for 16mmU ribs with hot rolling variable cross sections of extra-large bridges, which comprises the following steps: manufacturing a U-shaped rib plate, manufacturing the U-shaped rib plate by adopting a hot rolling forming technology, and ensuring that the thickness of a crown part of the U-shaped rib is 8 to 12mm, and the thickness of a root part of the U-shaped rib is 16 mm; welding groove processing; assembling: assembling a U-shaped rib plate on a bottom plate on a horizontal jig frame, and performing positioning welding on the bottom of the outer side of the U-shaped rib plate; clearing, polishing and welding are carried out within the range of at least 20mm at the inner side and the outer side of the welding groove of the U rib plate; welding the inner sides of the U rib plates by using a special welding machine for U rib inner welding; the specific welding method comprises the following steps: solid wire gas shield welding with protective gas 80% Ar +20% CO2, welding wire specification ER50-6 (Φ 1.2); and (4) welding the outer side of the U-shaped rib plate by adopting a submerged arc special machine to complete welding. The invention firstly realizes 100% full penetration of a U rib plate unit with a 16mm thickness of a welding hot-rolling variable cross section in China.
Description
Technical Field
The invention relates to the field of bridge construction processes, in particular to a full penetration welding method for a hot-rolled variable cross-section 16mmU rib of an extra-large bridge.
Background
The orthotropic steel bridge deck slab is widely used in large and medium-span steel bridges at home and abroad by virtue of the advantages of light weight and high construction speed since the 1950 s, a large amount of investigation data show that the deck slab is easy to form local stress concentration at the inner side welding root of a U rib under the action of repeated wheel pressure, the stress concentration is a key factor causing fatigue damage of the deck slab of the steel bridge at the position, cracks generated at the position are not easy to be found, the maintenance cost is high, and in order to reduce the fatigue problem of the U rib welding position of the deck slab of the steel bridge caused by the repeated action of vehicle wheel load, the U rib full penetration technology is urgently required. With the continuous updating of equipment, the U-rib full-penetration technology is a key technology for manufacturing bridges.
In the existing bridge construction project, the U-shaped rib is generally obtained by bending and processing a steel plate, the thickness of the U-shaped rib is 8-12mm, external welding machinery or manual welding is adopted all the time, the welding penetration rate can only reach 80 percent or even lower, and the welding quality, the welding penetration depth and the instability are high.
The technical difficulty of full penetration of the U rib is as follows:
(1) The inner space of the U rib is small, the conventional welding machine cannot enter the U rib for welding, the welding seam of the U rib is long, electric arcs cannot be tracked in the welding process, and the repair treatment is inconvenient;
(2) The U-rib welding lines are dense, so that the U-rib welding lines are not required to be back-gouged, otherwise the flatness and the fatigue resistance of the top plate cannot be guaranteed, and therefore the requirement of full penetration can be met only by directly fusing the external welding with the internal welding with high heat input.
Disclosure of Invention
The invention aims to solve the technical problems and provides a full penetration welding method for 16mmU ribs with a hot-rolled variable cross section of an extra-large bridge, which is realized by the following technical scheme:
the full penetration welding method for the hot-rolled variable cross-section 16mmU rib of the extra-large bridge is characterized by comprising the following steps of:
step 1: manufacturing a U-shaped rib plate, manufacturing the U-shaped rib plate by adopting a hot rolling forming technology, and ensuring that the thickness of a crown part of the U-shaped rib is 8 to 12mm, and the thickness of a root part of the U-shaped rib is 16 mm;
and 2, step: processing a welding groove, namely processing the welding groove at the root of the U rib plate, wherein the angle of the groove is 52 degrees, and the truncated edge is 1.5mm-2mm;
and 3, step 3: assembling; assembling a U-shaped rib plate on a bottom plate on a horizontal jig frame, wherein the assembling clearance is less than or equal to 0.5mm, and performing positioning welding on the bottom of the outer side of the U-shaped rib plate; specifically, the assembly clearance is less than or equal to 0.5mm, a 75mm welding seam is spot-welded at intervals of 400mm to form tack welding, the tack welding size is ensured to be between 4 and 6mm, and the tack welding position is polished to ensure that the tack welding area can be completely fused in the subsequent external submerged arc welding operation;
and 4, step 4: cleaning, polishing and welding are carried out within the range of at least 20mm at the inner side and the outer side of the welding groove of the U-shaped rib plate;
and 5: welding the inner sides of the U rib plates by using a special welding machine for U rib inner welding; the specific welding method comprises the following steps: gas shielded welding with solid wire, protective gas 80% Ar +20% CO2, welding wire specification ER50-6 (phi 1.2);
step 6: welding the outer side of the U rib plate by adopting a submerged arc special machine; the welding material is F7A4-H10Mn2 (phi 3.2 mm); the angle between the welding gun and the plate unit is controlled to be 44-45 degrees, and the welding wire foot falling point is ensured to be opposite to the root of the welding line; thereby completing the welding.
The full penetration welding method for the hot-rolled variable cross-section 16mmU rib of the extra-large bridge is further designed in the step 5, the special welding machine for the internal welding of the U rib is provided with a telescopic arm longitudinally extending from one end of the U rib plate to the inner side of the U rib plate, and welding guns opposite to a welding seam are symmetrically arranged on two sides of the front part of the telescopic arm; the telescopic arm is provided with a sliding plate capable of longitudinally sliding at the rear side of the welding gun, the telescopic arm is hinged with a damping rod positioned at one longitudinal side of the sliding plate, and the end part of the damping rod is rotatably connected with a damping sleeve; an elastic piece for driving the shock absorption rod to approach the telescopic arm is arranged at the hinged position of the shock absorption rod and the telescopic arm, a slope plate opposite to the sliding plate is arranged at the position, close to the telescopic arm, of the shock absorption rod, the sliding plate is connected with a linear driving mechanism, and when the sliding plate moves towards the direction of the slope plate, the shock absorption rod stretches to enable the shock absorption sleeve to abut against the inner wall of the U-shaped rib plate; when the sliding plate moves back to the direction of the slope plate, the shock absorption rod is close to the telescopic arm under the action of elasticity.
The full penetration welding method for the 16mmU ribs with the hot-rolled variable cross sections of the extra-large bridge is further characterized in that a sliding section is arranged at the upper part of the rear side of the welding gun of the telescopic arm, the middle part of the upper side face of the sliding section is sunken, the sliding plate is adaptive to the sliding section in shape and is arranged in the sliding section, and the shock absorption rod is also positioned in the sliding section.
The invention has the beneficial effects that:
firstly, the plate thickness of a welding area at the end of the U-shaped rib plate is increased to 16mm from 8-12mm, the thickness of a welding seam between the U-shaped rib and a face bottom plate is increased, and the anti-fatigue capability of the welding position of the U-shaped rib of the steel bridge deck is improved; in order to not increase the total weight of the steel bridge, the forming process of the U rib plate is innovated, the original steel plate bending processing technology is changed into the one-step forming of the U rib plate through a hot rolling technology, and finally the variable cross-section U rib plate with the thickness of 8-12mm at the crown part of the U rib and the thickness of 16mm at the root part of the U rib is formed.
Because U rib length usually reaches about 10 meters to usually a plurality of telescopic booms are connected in the special welding machine of walking longmen U rib internal welding, have formed uncontrollable complicated vibration source to the welder, set up the shock attenuation pole in welder's rear side, can effectively reduce welding gun's among the welding operation process vibration phenomenon, ensure to weld accurately, thereby further ensure the welding seam quality.
Because the inside of the U rib can not be repaired manually, the conventional flux-cored gas shielded welding is adopted, the flux coating in the U rib can not be removed, the appearance of a welding seam is difficult to observe, whether the welding seam is qualified can not be judged, the solid welding wire splashes more, is poor in forming and is easy to block a gun head, and the bottleneck of the internal welding technology research is solved, so that the solid welding wire mixed gas shielded welding is adopted, and the welding problem is effectively avoided.
The outer welding adopts a submerged arc special machine for welding, the special machine is provided with a mechanical tracking system and a welding flux recovery system, the angle of a jig frame, the angle of a welding gun, the angle of a groove and welding parameters are determined according to a series of tests, and the requirement of full penetration of a welding seam is ensured in many aspects.
Drawings
FIG. 1 is a schematic view of a hot rolled variable cross section U-rib of the present invention.
FIG. 2 is a schematic diagram of a welding state of the special U-rib inner welding machine.
FIG. 3 is a schematic view of a special submerged-arc welding machine for the outer side of a U rib.
Fig. 4 is a side view of the shock-absorbing rod.
FIG. 5 is a sectional view of a slide plate for driving a damper rod.
Fig. 6 is a schematic view of the shock-absorbing rod in a lower side view.
Detailed Description
The invention is further illustrated by the following figures and examples in conjunction with the description:
the 11m plate unit adopted in the embodiment is derived from a second east passage project product plate unit of a mansion door, the robot penetration research of the welding is carried out on the U rib with the thickness of 16mm of the hot-rolled variable cross section, the welding length of the welding seam is 11 meters, and the full penetration rate of the standard requirement reaches more than 95%.
The full penetration welding method for the 16mmU rib with the hot-rolled variable cross section of the super-large bridge is characterized by comprising the following steps of:
step 1: manufacturing a U-shaped rib plate 1, and manufacturing the U-shaped rib plate by adopting a hot rolling forming technology in combination with the structure shown in the figure 1, wherein the thickness of a crown part 11 of the U-shaped rib is 8-12mm, and the thickness of a root part 12 of the U-shaped rib is 16 mm; step 2: and (3) processing a welding groove 13 at the root of the U-shaped rib plate, wherein the angle of the groove is 52 degrees, and the thickness of the truncated edge 14 is 1.5mm-2mm.
And 3, step 3: assembling; assembling the U rib plate on the bottom plate on the horizontal jig frame, wherein the assembling clearance is less than or equal to 0.5mm, and performing positioning welding on the bottom of the outer side of the U rib plate; specifically, the assembly clearance is less than or equal to 0.5mm, a 75mm welding seam is spot-welded at intervals of 400mm to form tack welding, the tack welding size is ensured to be between 4 mm and 6mm, and the tack welding position is polished to ensure that the tack welding area can be completely fused in the subsequent external submerged arc welding operation.
And 4, step 4: clearing, polishing and welding are carried out within the range of at least 20mm at the inner side and the outer side of the welding groove of the U rib plate; to remove primer, oxide, moisture, oil stain and the like; and 5: welding the inner sides of the U rib plates by using a special welding machine 2 for welding the U rib; the specific welding method comprises the following steps: gas shielded welding with solid wire, protective gas 80% Ar +20% CO2, welding wire specification ER50-6 (phi 1.2); internal welding parameters: the elongation of the welding wire is 25mm; the gas flow is 20L/min; a welding current 320A; welding voltage is 31V; the welding speed is 340mm/min; and 6: welding the outer side of the U-shaped rib plate by adopting a submerged arc special machine 3; the submerged arc special machine 3 is provided with a laser tracking mechanism 31, a welding flux conveying pipe 32, a submerged arc welding gun 33 and a welding flux recycling pipe 34, wherein the laser tracking mechanism 31 performs tracking confirmation on a welding part, the welding conveying pipe 32 lays welding flux 35 on the welding part, the submerged arc welding gun 33 performs welding, and the welding flux recycling pipe 34 recycles the welding flux which does not participate in the operation; and adopting a thick wire with the diameter of 3.2mm for submerged-arc welding, and welding a welding material F7A4-H10Mn2. External welding parameters: the elongation of the welding wire is 25mm; welding current 620A; welding voltage 31V; the welding speed is 380mm/min. The angle between the welding gun and the plate unit is controlled to be 44-45 degrees, and the welding wire foot point is ensured to be opposite to the root of the welding line; thereby completing the welding.
After completion of the operation, the hot-rolled variable-section U-rib weld 100% UT +100% MT was subjected to nondestructive testing with a flaw detection yield of 100%. And (4) cutting a macroscopic sample of the welding seam, and displaying full penetration of the welding seam through macroscopic inspection of the section, wherein the forming is good.
Compared with the mode that the U rib and the face bottom plate are welded externally in general in the industry, the invention combines the hot-rolled U rib and the face bottom plate with the variable cross section of 16mm in thickness, the inside solid welding wire mixed gas shielded welding strengthens the seam backing technology, the outside submerged arc welding special machine full penetration technology, and the 100% full penetration of the hot-rolled U rib plate unit with the variable cross section of 16mm in thickness is welded for the first time in China.
Considering that the U-rib length is usually about 10 meters, and a plurality of telescopic arms are usually connected to the special U-rib inner welding machine 2 of the walking gantry, an uncontrollable complex vibration source is formed for the welding gun, and the embodiment is improved as follows: in the step 5, the special welding machine for the U-rib inner welding is provided with a telescopic arm 21 which longitudinally extends from one end of the U-rib plate to the inner side of the U-rib plate, and welding guns 22 opposite to the welding seam are symmetrically arranged on two sides of the front part of the telescopic arm; the telescopic arm is provided with a sliding plate 23 capable of longitudinally sliding at the rear side of the welding gun, the telescopic arm is hinged with a damping rod 24 positioned at one longitudinal side of the sliding plate, and the end part of the damping rod is rotatably connected with a damping sleeve 25; an elastic piece for driving the shock absorption rod to approach the telescopic arm is arranged at the hinged position of the shock absorption rod and the telescopic arm, a slope plate 241 opposite to the sliding plate is arranged at the position, close to the telescopic arm, of the shock absorption rod 24, the sliding plate is connected with a linear driving mechanism, and when the sliding plate moves towards the slope plate, as shown in figure 6, the shock absorption rod is expanded to enable the shock absorption sleeve to be abutted against the inner wall of the U-shaped rib plate 1, so that the vibration phenomenon of the front part of the telescopic arm is eliminated; when the sliding plate moves back to the direction of the slope plate, the shock absorption rod is close to the telescopic arm under the action of elasticity.
As shown in fig. 5, the telescopic arm is provided with a sliding section at the upper part of the rear side of the welding gun, the upper side surface of the sliding section is sunken, the shape of the sliding plate is adapted to the sliding section and is arranged in the sliding section, and the shock absorption rod is also positioned in the sliding section.
Claims (3)
1. The full penetration welding method for the hot-rolled variable cross-section 16mmU rib of the extra-large bridge is characterized by comprising the following steps of:
step 1: manufacturing a U-shaped rib plate, manufacturing the U-shaped rib plate by adopting a hot rolling forming technology, and ensuring that the thickness of a crown part of the U-shaped rib is 8 to 12mm, and the thickness of a root part of the U-shaped rib is 16 mm;
step 2: processing a welding groove, namely processing the welding groove at the root of the U rib plate, wherein the angle of the groove is 52 degrees, and the truncated edge is 1.5mm-2mm;
and 3, step 3: assembling; assembling the U rib plate on the bottom plate on the horizontal jig frame, wherein the assembling clearance is less than or equal to 0.5mm, and performing positioning welding on the bottom of the outer side of the U rib plate; specifically, the assembly clearance is less than or equal to 0.5mm, a 75mm welding seam is spot-welded at intervals of 400mm to form tack welding, the tack welding size is ensured to be between 4 and 6mm, and the tack welding position is polished to ensure that the tack welding area can be completely fused in the subsequent external submerged arc welding operation;
and 4, step 4: clearing, polishing and welding are carried out within the range of at least 20mm at the inner side and the outer side of the welding groove of the U rib plate;
and 5: welding the inner sides of the U rib plates by using a special welding machine for U rib inner welding; the specific welding method comprises the following steps: gas shielded welding with solid wire, protective gas 80% Ar +20% CO2, welding wire specification ER50-6 (phi 1.2);
and 6: welding the outer side of the U rib plate by adopting a submerged arc special machine; the welding material is F7A4-H10Mn2 (phi 3.2 mm); the angle between the welding gun and the plate unit is controlled to be 44-45 degrees, and the welding wire foot falling point is ensured to be opposite to the root of the welding line; thereby completing the welding.
2. The full penetration welding method for the hot-rolled variable-cross-section 16-mmU rib of the extra-large bridge according to claim 1, characterized in that in the step 5, the special welding machine for welding the U rib is provided with a telescopic arm longitudinally extending from one end of the U rib plate to the inner side of the U rib plate, and welding guns opposite to a welding seam are symmetrically arranged on two sides of the front part of the telescopic arm; the telescopic arm is provided with a sliding plate capable of longitudinally sliding at the rear side of the welding gun, the telescopic arm is hinged with a damping rod positioned at one longitudinal side of the sliding plate, and the end part of the damping rod is rotatably connected with a damping sleeve; an elastic piece for driving the shock absorption rod to approach the telescopic arm is arranged at the hinged position of the shock absorption rod and the telescopic arm, a slope plate opposite to the sliding plate is arranged at the position, close to the telescopic arm, of the shock absorption rod, the sliding plate is connected with a linear driving mechanism, and when the sliding plate moves towards the direction of the slope plate, the shock absorption rod stretches to enable the shock absorption sleeve to abut against the inner wall of the U-shaped rib plate; when the sliding plate moves back to the direction of the slope plate, the shock absorption rod is close to the telescopic arm under the action of elasticity.
3. The full penetration welding method for the 16mmU ribs with the hot rolled variable cross sections of the extra-large bridge according to claim 2, characterized in that the telescopic arm is provided with a sliding section at the upper part of the rear side of the welding gun, the upper side surface of the sliding section is concave, the shape of the sliding plate is adapted to the sliding section and is arranged in the sliding section, and the shock absorption rod is also positioned in the sliding section.
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| CN202110622659.0A CN115430887A (en) | 2021-06-04 | 2021-06-04 | Full penetration welding method for 16mmU rib with hot-rolled variable cross section of extra-large bridge |
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| CN202110622659.0A CN115430887A (en) | 2021-06-04 | 2021-06-04 | Full penetration welding method for 16mmU rib with hot-rolled variable cross section of extra-large bridge |
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