CN115502598A - Manufacturing method of ultra-large axial flow compressor shell - Google Patents
Manufacturing method of ultra-large axial flow compressor shell Download PDFInfo
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- CN115502598A CN115502598A CN202211159421.XA CN202211159421A CN115502598A CN 115502598 A CN115502598 A CN 115502598A CN 202211159421 A CN202211159421 A CN 202211159421A CN 115502598 A CN115502598 A CN 115502598A
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- 238000004519 manufacturing process Methods 0.000 title claims description 40
- 238000003466 welding Methods 0.000 claims abstract description 120
- 238000000034 method Methods 0.000 claims abstract description 44
- 238000012360 testing method Methods 0.000 claims description 18
- 238000007789 sealing Methods 0.000 claims description 16
- 238000003754 machining Methods 0.000 claims description 9
- 238000012545 processing Methods 0.000 claims description 8
- 238000001816 cooling Methods 0.000 claims description 6
- 238000004321 preservation Methods 0.000 claims description 6
- 230000006641 stabilisation Effects 0.000 claims description 5
- 238000011105 stabilization Methods 0.000 claims description 5
- 230000002706 hydrostatic effect Effects 0.000 claims description 3
- 230000008569 process Effects 0.000 abstract description 21
- 238000003672 processing method Methods 0.000 abstract description 2
- 238000010438 heat treatment Methods 0.000 description 14
- 230000000694 effects Effects 0.000 description 9
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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
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or 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
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/003—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to controlling of welding distortion
Abstract
The invention belongs to a shell processing method, and aims to solve the technical problems that in the existing axial flow compressor, the assembly precision and the service life of a welded shell are greatly influenced by a welding process due to the structural characteristics of the welded shell, and the welding process capable of improving the shell quality is urgently needed.
Description
Technical Field
The invention belongs to a machine shell processing method, and particularly relates to a method for manufacturing a machine shell of an ultra-large axial flow compressor.
Background
The axial flow compressor is of a horizontal split type, air is axially fed, air is radially discharged downwards, and a middle split surface is connected by a prestressed bolt. The casing and the inner blade bearing cylinder form a double-layer cylinder structure, so that the internal pressure and distortion caused by temperature change are reduced to the minimum, the unit is firm and durable, and the noise is low.
In the manufacturing industry of axial flow compressors, the casing generally adopts a casting structure, and has the problems of high cost, long period, scarce resources, serious environmental pollution and the like. With the development of large-scale equipment, the manufacturing of the cast machine shell is more difficult, and the welded machine shell has great advantages in the aspects of cost, period, environmental protection and the like due to light weight, so that the welded machine shell is widely popularized and applied. However, due to the structural characteristics of the welding enclosure, if the welding process is not properly designed, the welding enclosure structure may generate large deformation and residual stress, which will seriously affect the assembly accuracy and the service life of the enclosure. Therefore, a welding process capable of improving the quality of the cabinet is urgently required.
Disclosure of Invention
The invention provides a manufacturing method of an ultra-large axial flow compressor shell, aiming at solving the technical problems that in the existing axial flow compressor, the assembly precision and the service life of the shell are greatly influenced by a welding process due to the structural characteristics of the welded shell, and the welding process capable of improving the quality of the shell is urgently needed.
In order to achieve the purpose, the invention adopts the following technical scheme to realize the purpose:
a manufacturing method of a super-large axial flow compressor shell is characterized by comprising the following steps:
s1, welding of each part of an upper shell and each part of a lower shell in a shell of the ultra-large axial flow compressor respectively;
s2, completing the whole welding of the upper shell and the partial welding of the lower shell by adopting the following methods respectively:
sequentially welding the sealing plate assembly and the shell flange, and the shell flange; respectively welding end covers at two ends of the shell with the shell, the sealing plate assemblies and the shell flanges in a tack welding manner, and then welding the end covers at the two ends of the shell with the shell flanges, the end covers with the shell, and the end covers with the adjacent sealing plate assemblies; finally, welding the inclined supporting plate assembly and the shell, and welding the supporting plate and the shell;
s3, welding an air inlet cylinder and an air outlet cylinder at an air inlet and an air outlet on the side wall of the lower shell through an air inlet flange and an air outlet flange respectively to complete the whole welding of the lower shell;
s4, keeping the temperature of the upper machine shell and the lower machine shell at the constant temperature of 280-320 ℃ for 3-5h, keeping the temperature at 500-600 ℃ for 8-12h, and cooling to the normal temperature;
s5, preserving heat for 6-10h at 400-500 ℃;
s6, connecting the upper shell and the lower shell, respectively carrying out shell strength test on the upper shell and the lower shell through a hydrostatic test, if the test is qualified, executing the step S7, otherwise, overhauling or scrapping;
and S7, contacting the connection of the upper shell and the lower shell to complete the machining of the shell of the ultra-large axial flow compressor.
Further, in the step S2, when the end cover and the shell are welded, the weld joint is a single U-shaped groove;
when the end cover and the shell flange are welded, the welding seam is a double-U-shaped groove;
when the supporting plate and the shell are welded, a welding seam is a single V-shaped groove;
in the step S3, when the air inlet flange and the shell and the air outlet flange and the shell are welded, the welding line is a single U-shaped groove.
Further, in step S3, the air inlet flange and the air inlet drum are connected by welding, the air outlet flange and the air outlet drum are connected by welding, and welding seams are single V-shaped grooves with blunt edges during welding;
in the step S1, an air inlet cylinder and an air outlet cylinder in a lower shell are both of two-part split type structures, and an X-shaped groove is adopted when the two parts are welded; wherein, the two parts of the air inlet cylinder and the air outlet cylinder are the two parts equally divided by the end surfaces thereof along the axial extension plane.
Further, in the step S1, when welding the two parts of the air inlet cylinder and the air outlet cylinder, respectively installing a support member inside the two ends of the air inlet cylinder and the air outlet cylinder, then welding, and then removing the support member;
further, in the step S2, when the end cover and the shell are welded, the truncated edge is 4mm;
in step S3, when the air inlet flange and the casing, and the air outlet flange and the casing are welded, the truncated edge is 4mm.
Further, the step S4 specifically comprises the steps of placing the upper casing and the lower casing in a gas furnace, preserving heat for 4 hours at the constant temperature of 300 ℃, preserving heat for 10 hours at the temperature of 550 ℃, and cooling to the normal temperature; when the upper casing and the lower casing are placed, the flanges of the casings are placed downwards and are leveled.
Further, in step S4, after the constant temperature of 300 ℃ is kept for 4h, the temperature is raised to 550 ℃ at the rate of 50 ℃/h.
Further, the step S5 specifically comprises the steps of placing the upper casing and the lower casing in a gas furnace, heating to 460 ℃ at the speed of 50 ℃/h, and preserving heat for 6h at 460 ℃; when the upper casing and the lower casing are placed, the flanges of the casings are placed downwards and are leveled.
Further, a step S2-3 is included between the step S2 and the step S3, and a plurality of deformation supports are axially arranged on the shell flange;
and step S3-4 is also included between step S3 and step S4, and the deformation support is removed.
Further, the step S4 and the step S5 further include rough machining:
and respectively placing the upper shell and the lower shell on a gantry mill for leveling and processing, and reserving 2-3mm of allowance on the single side of a processed surface.
Compared with the prior art, the invention has the following beneficial effects:
1. the manufacturing method of the ultra-large axial flow compressor shell is designed aiming at the ultra-large axial flow compressor shell, and through multiple verification and inspection, compared with other welding process flows, the welding deformation is small, the internal stress of the shell is small, and the final high-precision machining requirement of the shell can be ensured. The manufacturing method of the invention has strong universality, is suitable for manufacturing the casings of the ultra-large axial flow compressors with different sizes, and is actually applied to the manufacturing verification of more than 20 products. According to practical verification, compared with a cast shell, the welded shell manufactured by the method can reduce the manufacturing cost by about 50 ten thousand yuan, and the manufacturing period can be greatly shortened.
2. The invention relates to a welding process, a post-welding stress relief treatment and stabilization treatment process after welding, and provides a specific process method.
3. The invention provides corresponding design schemes of the groove and the truncated edge in a matching way, and by matching with the welding method, the welding deformation can be reduced to the maximum extent, and the welding effect is further improved.
4. The deformation support is arranged on the shell flange during welding, so that the deformation in the welding process can be effectively reduced.
Drawings
FIG. 1 is a schematic view of the overall structure of a super-large axial flow compressor casing according to an embodiment of the present invention (showing the component structures inside the upper casing and the lower casing);
FIG. 2 is a schematic view of a shell in a super large axial compressor shell in an embodiment of the present invention (only one-quarter of the shell is shown in the circumferential direction);
FIG. 3 is a schematic view of an air inlet barrel in a casing of an ultra-large axial flow compressor according to an embodiment of the present invention;
FIG. 4 is a schematic view of an air outlet cylinder in a housing of an ultra-large axial flow compressor in an embodiment of the present invention;
FIG. 5 is a schematic view of an inclined support plate assembly in an ultra-large axial compressor casing according to an embodiment of the present invention (only one quarter of the inclined support plate assembly in the circumferential direction is shown);
FIG. 6 is a schematic view of a support plate in a super large axial compressor casing in an embodiment of the present invention (only one quarter of the support plate is shown in the circumferential direction);
FIG. 7 is a schematic view of a seal plate assembly in an ultra-large axial compressor casing in an embodiment of the present invention (only one-quarter of the seal plate assembly is shown in the circumferential direction);
FIG. 8 is a schematic groove diagram of the air inlet flange and the shell during welding according to the embodiment of the present invention;
FIG. 9 is a schematic diagram of a groove formed when an end cover and a shell flange are welded according to an embodiment of the invention;
FIG. 10 is a schematic groove diagram of the air outlet cylinder during two half welding in the embodiment of the invention;
FIG. 11 is a schematic groove diagram of the air outlet flange and the air outlet cylinder during welding in the embodiment of the invention;
FIG. 12 is a schematic diagram of a bevel in the welding of the inclined strut plate assembly and the housing in an embodiment of the invention;
FIG. 13 is a schematic flow chart of a method for manufacturing a shell of an ultra-large axial flow compressor according to the present invention.
Wherein: 1-upper casing, 2-lower casing, 3-sealing plate assembly, 4-casing flange, 5-casing, 6-end cover, 7-air inlet cylinder, 8-air outlet cylinder, 9-air inlet flange, 10-air outlet flange, 11-inclined supporting plate assembly and 12-supporting plate.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. The components of embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations.
When the ultra-large axial flow compressor casing is manufactured, the whole casing is generally divided into two halves, the half casing and parts in the half casing are manufactured respectively, and then the two halves of the casing are connected together to complete the integral manufacturing of the casing. Fig. 1 is a schematic structural diagram of a super-large axial flow compressor casing, which includes an upper casing 1 and a lower casing 2, and casing flanges 4 are axially disposed on two sides of the upper casing 1 and the lower casing 2 for connecting the upper casing 1 and the lower casing 2 subsequently. An air inlet and an air outlet are formed in the side wall of the lower shell 2, and the air inlet cylinder 7 and the air outlet cylinder 8 are welded to the air inlet and the air outlet of the lower shell 2 through an air inlet flange 9 and an air outlet flange 10 respectively. All be provided with annular end cover 6 on the terminal surface of upper casing 1 and 2 both ends of lower casing, upper casing 1 all is provided with two closing plate subassembly 3 with 2 inside of lower casing, an inclined support plate subassembly 11 and a backup pad 12, 6 internal surfaces of end cover at upper casing 1 or 2 both ends of lower casing are connected respectively to two closing plate subassembly 3 one end, backup pad 12 is close to the closing plate subassembly 3 of one end, make the air intake be located between closing plate subassembly 3 and the backup pad 12, inclined support plate subassembly 11 is located the one end that is close to the air outlet, inclined support plate subassembly 11 still has the water conservancy diversion effect concurrently.
The ultra-large axial flow compressor has a large shell, and when the shell is manufactured by adopting a welding mode, the welding process has important influences on the assembly precision and the service life of the shell, including but not limited to the welding sequence, the specific welding mode, the treatment method after welding and the like. The invention provides a manufacturing method of an ultra-large axial flow compressor shell, which ensures the final size and precision requirements of the shell and solves the problems that the manufacturing precision of the large axial flow compressor shell is high and the welding axial flow compressor shell has unsolvable deformation and over-tolerance in the manufacturing process. As shown in fig. 13, the specific manufacturing steps are as follows:
step one, blanking of each part
The length of a shell flange 4 in the shell of the ultra-large axial flow compressor can reach 7-8 meters generally, the thickness can reach 200-250mm, forging blanking is generally adopted from comprehensive analysis of quality and cost, and a certain size allowance is reserved on the side (thickness direction) of a processing surface during blanking.
The shell 5 of the upper shell 1 and the shell 5 of the lower shell 2 are respectively blanked according to the length in a segmented mode, 30-50mm of allowance is reserved in the circumferential direction, the allowance of the subsequent bent straight edge and the allowance of the part which cannot be bent are removed later.
The support plate 12, the inclined support plate component 11, the sealing plate component 3, the air inlet cylinder 7 and the air outlet cylinder 8 are all divided into two halves to be unfolded for blanking, and generally, plate blanking is performed, the two halves are two halves which are uniformly divided along an axial extension plane on any end surface, the two halves are correspondingly and respectively form the shell flange 4 in the upper shell 1 and the shell flange 4 in the lower shell 2, the shell 5, the support plate 12, the inclined support plate component 11 and the sealing plate component 3, the air inlet cylinder 7 and the air outlet cylinder 8 are also divided into two halves during blanking, the air inlet cylinder 7 and the air outlet cylinder 8 are welded into a complete air inlet cylinder 7 and an air outlet cylinder 8 after subsequent bending, and certain size allowance is reserved on one side in the circumferential direction and the side of a processing surface during blanking of the components.
The parts fed in the first step are all flat plate structures corresponding to all the parts, namely the part structures projected on the horizontal plane of all the parts, and the corresponding three-dimensional structures can be formed only after the bending in the second step.
In addition, each part can be of an integral structure or a split structure, and if the parts are of the split structures, each part is respectively blanked.
Step two, bending
The supporting plate 12, the inclined supporting plate component 11, the sealing plate component 3 and the shell 5 are formed by rolling and bending through a rolling machine, and redundant straight sections are removed through gas cutting. The air inlet cylinder 7 and the air outlet cylinder 8 are also respectively pressed by a press machine, radioactive rays are marked before pressing, and pressing is carried out by a pressing mould.
After the two halves of the air inlet cylinder 7 and the air outlet cylinder 8 are pressed, the supporting pieces can be arranged inside the two ends, and after the two halves of the air inlet cylinder 7 and the air outlet cylinder 8 are assembled and spot welded, the supporting pieces are removed and then welded. In addition, if the housing 5 is a split structure, the support members may be provided inside both ends of each split part before welding after the split parts are bent, and removed after welding.
Step three, respectively completing the welding of each part of the upper casing 1 and each part of the lower casing 2 in the ultra-large axial flow compressor casing
Because the volume of the ultra-large axial flow compressor shell is large, the volume of each part is also large, and each part in the upper shell 1 and the lower shell 2 is generally in a split structure, each part of each part needs to be welded firstly to obtain complete parts.
Referring to fig. 2, the housing 5 is a three-section structure, and the three sections are welded to form the complete housing 5. Fig. 3 and 4 are schematic structural diagrams of an air inlet cylinder 7 and an air outlet cylinder 8 respectively, the air inlet cylinder 7 and the air outlet cylinder 8 in the upper shell 1 and the lower shell 2 are both of two-part split structures, when the two parts are welded, an X-shaped groove is adopted, the two parts of the air inlet cylinder 7 and the air outlet cylinder 8 are both equally divided along an axial extension plane from the end surfaces of the two parts, and the air inlet cylinder 7 can be divided into more parts due to the fact that the curved surface shape of the side wall of the air inlet cylinder 7 is more complex. Fig. 5, fig. 6 and fig. 7 are schematic structural diagrams of the inclined strut plate assembly 11, the support plate 12 and the seal plate assembly 3, respectively, and it can also be seen from the drawings that the inclined strut plate assembly 11, the support plate 12 and the seal plate assembly 3 are specifically composed of a plurality of small components, and the small components are welded to form the whole component.
Step four, welding the upper shell 1 and the lower shell 2
After the welding manufacturing of the above parts is completed, the upper casing 1 and the lower casing 2 can be welded respectively, and the specific welding sequence is as follows:
(1) The upper case 1 and the lower case 2 are welded in the following order
a. And (3) respectively performing tack welding on the two sealing plate assemblies 3 and the shell flange 4, and then welding bilateral welding seams of the two sealing plate assemblies and the shell flange 4.
b. Spot welding is carried out on the shell 5 and the shell flange 4, and then welding seams at two sides of the shell 5 and the shell flange 4 are welded;
c. respectively tack-welding two end covers 6 with a shell 5, a sealing plate assembly 3 and a shell flange 4, then welding bilateral welding seams of the two end covers 6 and the shell flange 4, then welding excircle welding seams of the two end covers 6 and the shell 5, and then welding excircle welding seams of the two end covers 6 and the adjacent sealing plate assembly 3;
d. 3 deformation supports are uniformly and axially arranged on the shell flange 4, and the installation number of the deformation supports can be adjusted according to the axial length of the shell 5;
e. positioning at the air inlet side, fixedly welding the inclined support plate assembly 11 and the support plate 12 with the shell 5 respectively, and uniformly and symmetrically welding double-side welding seams;
f. and removing the deformation support, and completing the whole welding of the upper shell 1 and the partial welding of the lower shell 2.
(2) Completing the welding of the lower case 2
Firstly, an air inlet and an air outlet are formed by lofting and opening holes on the side wall of the shell plate of the lower shell 2, and then an air inlet cylinder and an air outlet cylinder are respectively welded. Specifically, an air inlet and an air outlet are respectively arranged on the side wall of the lower shell 2, the arrangement positions are determined according to the design of the ultra-large axial flow compressor shell, an air inlet cylinder 7 and an air outlet cylinder 8 are welded at the air inlet and the air outlet through an air inlet flange 9 and an air outlet flange 10, the lower shell 2 is completely welded, the air inlet cylinder 7 and the air outlet cylinder 8 are respectively welded on the air inlet flange 9 and the air outlet flange 10, and then the air inlet flange 9 and the air outlet flange 10 are respectively welded on the shell 5 at the air inlet and the air outlet.
When the concrete welding of the third step and the fourth step is finished, the groove and the truncated edge during welding are designed, and when the following requirements are met, the welding effect and the quality of the shell are better:
as shown in fig. 8, when the air inlet flange 9 and the shell 5 are welded, the single U-shaped groove with the truncated edge is adopted, so that the welding filling amount can be reduced, the welding deformation is reduced, the manufacturability is good, the assembling precision can be ensured by the 4mm truncated edge, and the groove form can be adopted when the air outlet flange 10 is welded with the shell 5 and when the shell 5 and the end cover 6 are welded. Like figure 9, when end cover 6 and casing flange 4 welded, adopt two U area truncated edge grooves, can effectively reduce welding filling volume, reduce welding deformation, similarly, the precision can be guaranteed to assemble by the 4mm truncated edge. As shown in fig. 10, when two halves of the air outlet cylinder 8 are welded, an X-shaped groove is adopted, so that the welding filling amount can be reduced, the welding deformation can be reduced, the manufacturability is good, and the groove design is the same for the air inlet cylinder 7. As shown in fig. 11, when the air outlet flange 10 and the air outlet cylinder 8 are welded, the groove is designed to be a single V groove with a truncated edge, the groove is formed on the air outlet flange 10, so that the end surface of the air outlet cylinder 8 can smoothly transition to the air outlet flange, and the same groove design is adopted for the air inlet cylinder 7. As shown in fig. 12, when the inclined supporting plate assembly 11 and the shell 5 are welded, a single-side fillet weld is designed, and a single V groove is formed on the inclined supporting plate assembly 11.
Fifthly, stress relief after welding
Respectively feeding the welded upper shell 1 and lower shell 2 into a gas furnace for overall stress relief treatment, wherein the stress relief treatment adopts a heat treatment mode, and the heat treatment process comprises the following steps: keeping the temperature at 280-320 ℃ for 4 hours, then raising the temperature to 500-600 ℃ at the heating rate of 50 ℃/hour, keeping the temperature at 500-600 ℃ for 8-12 hours, and cooling the furnace.
The test proves that under the constant temperature, the heat preservation time and the heating rate, a better stress relief effect can be obtained, the following is an optimal process, and the test proves that the better effect can be achieved only when the constant temperature and the heat preservation time of twice meet the following conditions:
keeping the temperature at 300 ℃ for 4 hours, heating to 550 ℃ at the heating rate of 50 ℃/hour, keeping the temperature at 550 ℃ for 8-12 hours, and cooling in the furnace.
Step six, carrying out stabilization treatment
The purpose of stable heat treatment is to remove processing stress, excessive allowance can cause overlarge internal stress after the completion of subsequent procedures, and insufficient allowance can cause deformation of the stable heat treatment procedure to be out of tolerance or insufficient allowance of subsequent finish machining, so that the final size precision of the shell is ensured. The stabilizing treatment process comprises the following steps: keeping the temperature for 5-7h at 400-500 ℃, wherein the optimal process in actual operation is as follows: heating to 460 ℃ at the heating rate of 50 ℃/hour, and keeping the temperature at 460 ℃ for 6 hours.
Step seven, hydrostatic test
After the upper shell 1 and the lower shell 2 complete the processing technology, the upper shell 1 and the lower shell 2 need to be held together through bolts, then a hydraulic test is carried out, the strength of the shell is tested, the pressure of the hydraulic test is generally 1.5 times of the working pressure, the pressure is kept for no less than 30 minutes, the hydraulic test can comprehensively detect the welding quality and the rigidity of a welding structure, if the hydraulic test of the upper shell 1 and the lower shell 2 is unqualified, reasons need to be found out, repair measures are made to repair until the hydraulic test is qualified, if the hydraulic test is qualified, the next step of installation can be carried out, and if the hydraulic test cannot be repaired to be qualified, only scrapping treatment can be carried out.
And step eight, after the test is finished, if the test is qualified, the bolt for connecting the upper shell 1 and the lower shell 2 is screwed off, and the upper shell 1 and the lower shell 2 are processed for standby.
In actual production, after the upper shell 1 and the lower shell 2 are machined through the steps, if the upper shell 1 and the lower shell 2 still have machining allowance, the upper shell 1 and the lower shell 2 can be respectively placed on a gantry mill for finish machining, and the machining allowance is eliminated.
In the above process, the most important is the overall assembly sequence of the casing and the heat treatment stress relief process of the casing, which greatly affects the manufacturing effect of the welded casing.
In order to verify the effect of the process, under the same other conditions, the welding sequence of the invention and other different welding sequences are adopted to manufacture the shell, under different welding sequences, the deformation conditions of all parts are different greatly, under one welding sequence different from the welding sequence of the invention, the position of the sealing plate component 3 generates large axial deformation, two sealing plate components 3 generate relative external expansion deformation of about 8mm, and the subsequent assembly and the use performance of other external joints are seriously influenced.
The process method is easy to operate, strong in popularization, capable of meeting the manufacturing requirements of welded shell products, and capable of greatly reducing the production cost and the production period compared with cast steel shells. Taking a certain AV100 model as an example, the production cycle of the cast steel shell comprises the steps of manufacturing a wood mold, pouring and cleaning, the welding shell is the total time of actual steel purchasing, blanking and welding, the manufacturing cost of the welding shell is reduced by 50 ten thousand yuan per machine compared with that of the casting shell, and the manufacturing cycle is reduced by 3 months. By adopting the assembling and welding scheme of the invention, the welding deformation is minimum, the deformation condition is detected by the optical three-coordinate measuring instrument, and the detection result and the calculation result have the same trend. Through numerical calculation, analysis and comparison, the welding deformation of other splicing and welding line schemes is greater than that of the scheme. And moreover, by adopting the assembling and welding method, the stress condition of the heat-treated shell is detected by a blind hole method, the detection result and the calculation result have the same trend, and the residual stress is higher than that of the scheme of the invention under the combination of other overhigh or overlow stress eliminating temperatures, overlong or overlong heat treatment heat preservation temperatures and other stress eliminating temperatures and heat treatment heat preservation temperatures through numerical analysis and comparison.
In addition, the invention also verifies the post-welding stress relief and stabilization treatment process, when only a certain constant temperature or a certain constant temperature time changes, the treatment effect changes correspondingly, and only when multiple parameters in the post-welding stress relief and stabilization treatment meet the requirements, the optimal processing effect can be achieved.
The above is only a preferred embodiment of the present invention, and is not intended to limit the present invention, and various modifications and changes will occur to those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. A manufacturing method of a super-large axial flow compressor shell is characterized by comprising the following steps:
s1, welding of each part of an upper shell (1) and each part of a lower shell (2) in a shell of the ultra-large axial flow compressor is respectively completed;
s2, the following methods are respectively adopted to complete the whole welding of the upper shell (1) and the partial welding of the lower shell (2):
sequentially welding the sealing plate assembly (3) and the shell flange (4), and welding the shell (5) and the shell flange (4); fixedly welding end covers (6) at two ends of the shell (5) with the shell (5), the sealing plate assembly (3) and the shell flange (4) respectively, and then welding the end covers (6) at two ends of the shell (5) with the shell flange (4), the end covers (6) with the shell (5), the end covers (6) with the adjacent sealing plate assembly (3); finally, welding the inclined support plate assembly (11) and the shell (6), and welding the support plate (12) and the shell (5);
s3, welding an air inlet cylinder (7) and an air outlet cylinder (8) at an air inlet and an air outlet on the side wall of the lower shell (2) through an air inlet flange (9) and an air outlet flange (10) respectively to complete the whole welding of the lower shell (2);
s4, keeping the temperature of the upper machine shell (1) and the lower machine shell (2) constant at 280-320 ℃ for 3-5h, keeping the temperature at 500-600 ℃ for 8-12h, cooling to normal temperature, and performing post-welding stress relief treatment;
s5, preserving heat for 6-10h at 400-500 ℃ and carrying out stabilization treatment;
s6, connecting the upper shell (1) and the lower shell (2), respectively carrying out shell strength test on the upper shell (1) and the lower shell (2) through a hydrostatic test, if the test is qualified, executing the step S7, otherwise, overhauling or scrapping;
and S7, removing the connection between the upper shell (1) and the lower shell (2) to complete the machining of the ultra-large axial flow compressor shell.
2. The method for manufacturing a shell of a very large axial flow compressor according to claim 1, wherein:
in the step S2, when the end cover (6) and the shell (5) are welded, a welding seam is a single U-shaped groove;
when the end cover (6) and the shell flange (4) are welded, the welding seam is a double-U-shaped groove;
when the supporting plate (12) and the shell (5) are welded, a welding seam is a single V-shaped groove;
in the step S3, when the air inlet flange (9) and the shell (2) and the air outlet flange (10) and the shell (2) are welded, the welding line is a single U-shaped groove.
3. The method for manufacturing a shell of a very large axial flow compressor according to claim 2, wherein:
in the step S3, the air inlet flange (9) is connected with the air inlet cylinder (7) in a welding mode, the air outlet flange (10) is connected with the air outlet cylinder (8) in a welding mode, and welding seams are single V-shaped grooves with truncated edges during welding;
in the step S1, an air inlet cylinder (7) and an air outlet cylinder (8) in a lower shell (2) are both of a two-part split structure, and an X-shaped groove is adopted when the two parts are welded; wherein, the two parts of the air inlet cylinder (7) and the air outlet cylinder (8) are respectively equally divided by the end surfaces thereof along the axial extension plane.
4. The method for manufacturing a shell of a very large axial flow compressor according to claim 3, wherein:
in the step S1, when the two parts of the air inlet cylinder (7) and the air outlet cylinder (8) are welded, the supporting pieces are respectively arranged inside the two ends of the air inlet cylinder (7) and the two ends of the air outlet cylinder (8), then the welding is carried out, and then the supporting pieces are removed.
5. The method for manufacturing a shell of an ultra-large axial flow compressor according to any one of claims 2 to 4, wherein:
in the step S2, when the end cover (6) and the shell (5) are welded, the truncated edge is 4mm;
in the step S3, when the air inlet flange (9) and the machine shell (2) and the air outlet flange (10) and the machine shell (2) are welded, the truncated edges are 4mm.
6. The method for manufacturing a shell of a very large axial flow compressor according to claim 5, wherein:
step S4, specifically, the upper casing (1) and the lower casing (2) are placed in a gas furnace, heat preservation is carried out for 4 hours at the constant temperature of 300 ℃, heat preservation is carried out for 10 hours at the temperature of 550 ℃, and cooling is carried out to the normal temperature; when the upper casing (1) and the lower casing (2) are placed, the casing flanges (4) are both placed downwards and are leveled.
7. The method for manufacturing a shell of a very large axial flow compressor according to claim 6, wherein:
in step S4, after the constant temperature of 300 ℃ is kept for 4h, the temperature is raised to 550 ℃ at the rate of 50 ℃/h.
8. The method for manufacturing a shell of a very large axial flow compressor according to claim 7, wherein:
step S5, specifically, the upper casing (1) and the lower casing (2) are placed in a gas furnace, the temperature is raised to 460 ℃ at the speed of 50 ℃/h, and the temperature is kept for 6h at 460 ℃; when the upper casing (1) and the lower casing (2) are placed, the casing flanges (4) are both placed downwards and are leveled.
9. The method for manufacturing a shell of a very large axial flow compressor according to claim 8, wherein: step S2-3 is also included between step S2 and step S3, and 2-3 deformation supports are arranged on the shell flange (4) along the axial direction;
and step S3-4 is also included between step S3 and step S4, and the deformation support is removed.
10. The method for manufacturing a shell of a very large axial flow compressor according to claim 9, wherein: the method also comprises rough machining between the step S4 and the step S5:
and respectively placing the upper shell (1) and the lower shell (2) on a gantry mill for leveling and processing, wherein 2-3mm of allowance is reserved on one side of a processing surface.
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