CN115805372B - Welding process of light-conducting box - Google Patents
Welding process of light-conducting box Download PDFInfo
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- CN115805372B CN115805372B CN202310046838.3A CN202310046838A CN115805372B CN 115805372 B CN115805372 B CN 115805372B CN 202310046838 A CN202310046838 A CN 202310046838A CN 115805372 B CN115805372 B CN 115805372B
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- 210000001503 joint Anatomy 0.000 claims description 17
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- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
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Abstract
The invention discloses a splice welding process of a light conduction box, which relates to the field of light conduction boxes, wherein the conduction box comprises a back frame, a front frame, a left side plate, a right side plate, a bottom plate and a top plate which are welded in pairs, and an inclined support piece welded among the back frame, the left side plate, the right side plate and the bottom plate; the welding process comprises the following steps: s1: welding parts; welding and fixing the bottom plate, the inclined support piece, the rear frame, the left side plate and the right side plate in pairs to form a semi-finished product piece; s2: performing first heat treatment; carrying out heat treatment on the semi-finished product piece to eliminate welding stress; s3: welding; welding the front frame and the rear frame on the basis of the semi-finished product after heat treatment to form a light conduction box; s4: and performing secondary heat treatment on the light conduction box to eliminate welding stress. The invention ensures that the light conduction box keeps stable structural dimension under the environment of long-term use, avoids the accumulation of process errors in the production process and ensures the installation precision of the reflecting mirror component.
Description
Technical Field
The invention relates to the field of light conduction boxes, in particular to a splice welding process of a light conduction box.
Background
The main functions of the large laser device light conduction box are to guide and transmit the laser beam (after the reflector is installed), and provide a stable and clean running environment for the laser beam. The light conduction box needs to ensure that the positions of the reflecting lenses arranged on the light conduction box are stable, and firstly, the relative positions of all parts of the light conduction box are ensured to be stable, namely, the parts forming the light conduction box cannot deform, so that the parts forming the light conduction box are prevented from shifting.
The main manufacturing material of the light conduction box is aluminum alloy, and the light conduction box has large volume and weight and more parts, so that more welding positions are caused; and each part is welded because of welding stress, the welding stress can lead to the shape and the size of the part to change, and the long-term stability of the structure size can not be ensured. For this reason, in order to reduce the influence of the stress generated during the welding process on the structural dimensions of the light-conducting box, the light-conducting box is usually subjected to a heat treatment during the production process to eliminate the welding stress generated during the welding process; however, in the current welding mode, the light-conducting box is assembled and finished in one time for heat treatment, and due to the accumulation of process errors, the shape and the size of the light-conducting box after heat treatment often meet the requirement that the deformation is more than one thousandth, or the dimensional tolerance and the form and position tolerance are more than 1mm, and the defect can influence the installation precision of the reflecting mirror assembly.
Disclosure of Invention
The invention aims at: aiming at the problems, the splice welding process of the light-conducting box is provided, so that the stability of the structural dimension of the light-conducting box can be ensured under the environment of long-term use, the accumulation of process errors in the production process can be effectively avoided, and the installation precision of the reflecting mirror component can be ensured.
The technical scheme adopted by the invention is as follows: the splice welding process of the light conduction box comprises a bottom plate and a top plate, wherein an inclined support piece for installing a reflector assembly is welded on the bottom plate, one end of the inclined support piece is welded with the bottom plate, and the other end of the inclined support piece is welded with a rear frame; the two sides of the inclined support piece are welded on the left side plate and the right side plate respectively; a front frame is welded on the bottom plate; the rear frame, the front frame, the left side plate, the right side plate, the bottom plate and the top plate are welded with each other; the method comprises the following steps:
s1: welding parts; welding and fixing the bottom plate, the inclined support piece, the rear frame, the left side plate and the right side plate in pairs to form a semi-finished product piece;
s2: performing first heat treatment; carrying out heat treatment on the semi-finished product piece to eliminate welding stress;
s3: welding; welding a front frame and a top plate to form a light conduction box on the basis of the semi-finished product after heat treatment;
s4: and performing secondary heat treatment on the light conduction box to eliminate welding stress.
Further, before proceeding to step S1, cleaning of the respective parts is required.
Further, after step S2 is completed, step S21 is performed: correcting the shape; and (5) performing shape correction on the semi-finished product according to the data requirements.
Further, after step S21 is completed, a support for supporting the mirror assembly is installed on the diagonal support.
Further, after the support is installed, the installation reference and the support surface of the reflector assembly of the support are subjected to a number of milling.
Further, in step S1 and step S3, the welding mode adopts laser welding.
Further, before step S1 and step S3, the welding is performed after the prefabricated butt joint step is required, that is, the prefabricated butt joint is performed on each part by using pins, and the butt joint combination interface is coated with the normal temperature curing resin adhesive.
Further, after the prefabricated butting step is completed, welding between the parts is completed within 3 hours.
Further, in step S1 and step S3, the type of welding at the time of the butt welding of the parts is any one of symmetrical fillet welding, symmetrical butt welding, and asymmetrical compound welding.
Further, the part material of the light conduction box is aluminum alloy 6061-T6 or aluminum alloy 5A06; in the step S2 or S4, the heat treatment mode is heating to 140-145 ℃ for 6061-T6 of aluminum alloy, preserving heat for 235-245 min, and discharging and air cooling; or heating the aluminum alloy 5A06 with a furnace, preserving heat for 1-1.5h at 310-330 ℃, discharging and air cooling after the heat preservation is finished.
In summary, due to the adoption of the technical scheme, the beneficial effects of the invention are as follows:
according to the invention, the whole light conduction box is split into two times of heat treatment, so that on one hand, the process error accumulation can be reduced, and the deformation of the shape and the size of the light conduction box after heat treatment can reach the requirement of less than one thousandth, or the dimensional tolerance and the form and position tolerance can reach the requirement of less than 1 mm; on the other hand, the stability of the structural dimension of the light conduction box can be ensured under the environment of long-term use, and the deformation of the light conduction box under the long-term action of welding stress is avoided.
Drawings
The invention will now be described by way of example and with reference to the accompanying drawings in which:
FIG. 1 is a schematic three-dimensional structure of a light conducting box according to the present disclosure;
FIG. 2 is a schematic diagram of a front view of a light box according to the present disclosure;
FIG. 3 is a schematic cross-sectional view of the structure of FIG. 2 in the direction A-A;
FIG. 4 is a schematic diagram of the welding process of step S3 of the present invention;
FIG. 5 is a schematic view of a symmetrical fillet weld according to the present invention;
FIG. 6 is a schematic illustration of a symmetrical butt weld according to the present invention;
FIG. 7 is a schematic illustration of an asymmetric composite weld in accordance with the present invention;
the marks in the figure: 1-a bottom plate; 2-inclined support members; 3-right side plate; 4-a front frame; 5-top plate; 6-a rear frame; 7-a support; 8-left side plate; 9-docking position; 10-pin holes; 11-first weld joint; 12-welding line II; 13-welding line III; 14-welding line IV; 15-welding line five; 16-welding line six.
Detailed Description
All of the features disclosed in this specification, or all of the steps in a method or process disclosed, may be combined in any combination, except for mutually exclusive features and/or steps.
Any feature disclosed in this specification may be replaced by alternative features serving the same or equivalent purpose, unless expressly stated otherwise. That is, each feature is one example only of a generic series of equivalent or similar features, unless expressly stated otherwise.
The bottom plate 1, the diagonal brace 2, the left side plate 8, the right side plate 3, the front frame 4, the rear frame 6, and the top plate 5 are collectively referred to as components in this specification.
Example 1
As shown in fig. 1 to 7, a splice welding process of a light conduction box, wherein the light conduction box comprises a bottom plate 1 and a top plate 5, a diagonal support 2 for installing a reflector assembly is welded on the bottom plate 1, one end of the diagonal support 2 is welded with the bottom plate 1, and the other end of the diagonal support 2 is welded with a rear frame 6; both sides of the inclined support piece 2 are welded to the left side plate 8 and the right side plate 3 respectively; a front frame 4 is welded on the bottom plate 1; the rear frame 6, the front frame 4, the left side plate 8, the right side plate 3, the bottom plate 1 and the top plate 5 are welded in pairs; the method comprises the following steps:
s1: welding parts; welding and fixing the bottom plate 1, the inclined support piece 2, the rear frame 6, the left side plate 8 and the right side plate 3 in pairs to form a semi-finished product piece;
s2: performing first heat treatment; carrying out heat treatment on the semi-finished product piece to eliminate welding stress;
s3: welding; welding the front frame 4 and the top plate 5 to form a light conduction box on the basis of the semi-finished product after heat treatment;
s4: and performing secondary heat treatment on the light conduction box to eliminate welding stress.
Specifically, in this embodiment, the diagonal brace 2 is welded between the bottom plate, the rear frame 6, the left side plate 8 and the right side plate 3, a triangular surface structure is formed between the bottom plate 1, the rear frame 6 and the diagonal brace 2, and the butt joint position 9 between the left side plate 8 or the right side plate 3 and the bottom plate 1, the diagonal brace 2 and the rear frame 6 forms a triangular structure, so that the mutual constraint between each part of the light conduction box is structurally improved, the dimensional stability of the light conduction box under the condition of long-term use is ensured, and the mounting position stability of the reflector is further ensured.
Further, in this embodiment, the light-conducting box is divided into two welding steps and two heat treatments, and the first heat treatment in step S2 eliminates the welding stress existing in the splice-welded part in step S1; the second heat treatment in the step S4 is to eliminate the welding stress existing in the welding in the step S3; the welding stress is eliminated gradually, so that the oversized dimensional change caused by stress accumulation in the welding process is avoided, and the purpose of reducing the process error is achieved; the deformation of the shape and the size of the light conduction box after heat treatment can reach the requirement of less than one thousandth, or the dimensional tolerance and the form and position tolerance can reach the requirement of less than 1 mm.
It should be noted that, in step S1, at least the bottom plate 1, the diagonal brace 2, the rear frame 6, the left side plate 8 and the right side plate 3 are welded, because the above parts are essential parts for fixing the diagonal brace 2 and stabilizing the brace 7, if one part is welded, there is a free deformation direction between the parts during the heat treatment process, and the purpose of mutual constraint cannot be achieved, so that the requirement of stabilizing the dimension cannot be satisfied.
Further, in the present embodiment, in step S1, the bottom portion should be welded in advance, for example, the bottom portion includes the bottom plate 1 and the supporting leg, and the bottom plate 1 and the supporting leg should be welded in advance; and after the bottom welding is finished, the mounting positions of other subsequent parts are machined, so that higher combination precision is formed, the integral deformation after direct splice welding can be effectively reduced, and the same mounting reference is provided for the mounting and welding of other parts mounted on the bottom.
In this embodiment, the welding sequence in step S3 is to weld the front frame 4 first and then weld the top plate 5, so that the top plate 5 can be supported during assembly, so as to achieve the purpose of reducing the variation in the mounting size of the top plate 5.
Example 2
Further embodiments are presented which can be implemented on the basis of example 1.
In an optional specific embodiment, before step S1 is performed, each part needs to be cleaned, mainly residues, impurities and greasy dirt on the surface of the part are cleaned, so that defects of inclusion, air holes and the like of the part in the assembling and welding process are reduced; specifically, in the welding process, residues and impurities on the surface of the part may enter the position of the welding position so that the welding position is mixed with impurities; grease ingress into the weld site can cause bubbles to form in the weld site.
In the embodiment, an organic solvent (such as absolute ethyl alcohol) is adopted to remove greasy dirt, and a nylon soft brush, a brush roller and the like are used for brushing the surface of the part; and then spraying clean water to the cleaning position by using a high-pressure spraying mode, and air-drying to finish the cleaning of the surface of the part. The beneficial effects of removing the greasy dirt by using the absolute ethyl alcohol as the organic solvent at least comprise the following points: firstly, the absolute ethyl alcohol is easy to volatilize, so that the existence of residues on the surfaces of parts is avoided; secondly, the absolute ethyl alcohol can be mixed with water in any proportion, so that the aim of easy removal during cleaning of the surface of the part is fulfilled. And secondly, the output pressure of high-pressure spraying is more than 15Mpa, so that residues and impurities on the surface of the part can be effectively removed.
In an alternative embodiment, after step S2 is completed, step S21 is performed: correcting the shape; performing shape correction on the semi-finished product according to the data requirements; the correction process is a prediction process, and is mainly used for correcting the shape and position tolerance (such as verticality, planeness, straightness and the like) which exceeds the requirement of the designed deformation; if not exceeded, no calibration may be required.
In the present embodiment, if the shape correction is required, the shape correction in step S21 must be performed after the first heat treatment in step S2 is completed; specifically, the sizing process is arranged after the first heat treatment in step S2 in order to restore excessive changes to the shape of the part during the heat treatment; if the step S21 of calibrating is performed before the first heat treatment in the step S2, the calibration process is restored to the design requirement of the geometric tolerance, but the material is deformed under the action of high temperature, and the tiny deformation generated by the welding butt joint position 9 when the welding stress is eliminated may be overlapped with the deformation generated by the calibration step, so that the deformation amount is uncontrollable; therefore, the step S21 of shaping must be performed after the first heat treatment of step S2 is completed.
An alternative embodiment, as shown in fig. 1-3, after step S21 is completed, a support 7 for supporting the mirror assembly is mounted on the diagonal support 2, the support 7 is a part for mounting the mirror assembly, the support 7 is mounted on the diagonal support 2, and the form and position tolerance of the diagonal support 2 is a root for ensuring the position of the support 7, thereby further ensuring the accuracy of the mounting position of the mirror assembly, so that the process of mounting the support 7 on the diagonal support 2 should be after the shape correction process.
In an alternative specific embodiment, after the supporting piece 7 is installed, a plurality of milling is performed on the installation reference and the supporting surface of the reflector assembly of the supporting piece 7, the plurality of milling is performed on the supporting piece 7, a numerical control five-axis machine tool is adopted for one-step machining in place, the required angle error is smaller than 10 milliradian, the position error is smaller than 0.07mm, the flatness is smaller than 0.05mm, and the accuracy and the precision of the installation position of the reflector assembly are ensured.
It should be noted that in step S1 and step S2, the advantage of not assembling the front frame 4 and the top plate 5 is that the milling head is convenient to process the milling position during the milling of the supporting member 7, so as to avoid the blocking effect of the cutter.
In the optional specific implementation manner, in the step S1 and the step S3, the welding mode adopts laser welding, the material of the part is aluminum alloy, deformation easily occurs during the welding process and after welding, and the assembly precision is affected.
An alternative embodiment, as shown in fig. 4, before the step S1 and the step S3, the welding is performed after the prefabricated butt joint step is required, that is, the prefabricated butt joint is performed on each part by using pins, and the normal-temperature curing resin adhesive is coated on a butt joint combined interface (that is, a butt joint position 9, a position encircled by a rectangular frame in fig. 4); in the embodiment, auxiliary tools are not selected for additional constraint and fixation of parts, the corresponding part precision is made into a design requirement (generally IT 6) before welding, and the pins for butt joint are prefabricated, so that the qualified size is formed by mutually matching the tools with higher precision as much as possible, and the purposes of saving cost and improving efficiency are achieved.
Specifically, before step S1 and step S3, the butt joint position 9 of the parts is coated with normal temperature curing resin glue, such as DG-3 resin glue; positioning and preassembling by using pins, checking the size, removing redundant normal-temperature curing resin adhesive after the normal-temperature curing resin adhesive is cured, cleaning a welding groove, and waiting for welding; the pin is matched with the pin hole 10 to realize positioning; as shown in fig. 4, the front frame 4 and the top plate 5 are prefabricated to be butted when they are welded.
In an alternative embodiment, after the prefabricated butt joint step is completed, the welding between the parts is completed within 3 hours, so that the phenomenon that the performance of the material is reduced due to excessive oxidation of the welding groove is avoided.
In the optional specific implementation manner, in the step S1 and the step S3, the welding type during the butt welding of the parts is any one of symmetrical fillet welding, symmetrical butt welding and asymmetrical compound welding, the welding type is selected according to the situation, and the butt welding is performed on the parts by adopting the three welding types, so that the deformation caused by overlarge welding stress during the local welding can be effectively controlled, and the result is obtained through a large number of process tests.
Specifically, if two parts are vertically abutted and the material of one part is provided with the material of the other part on both sides, symmetrical fillet welding is preferably adopted, and the symmetrical fillet welding (a first welding line 11 and a second welding line 12) is synchronously welded, as shown in fig. 5; if two parts are butted in parallel, symmetrical butt welding is preferably adopted, and the symmetrical butt welding (a third welding line 13 and a fourth welding line 14) is synchronously welded, as shown in fig. 6; if two parts are vertically butted and only one side of each part is provided with a material, preferably, an asymmetric composite welding is adopted, namely, welding fillet welding is firstly carried out (a welding line five 15), the fillet welding is positioned on the side provided with the material, then butt welding is carried out (a welding line six 16), and the butt welding is positioned on the side without the material, as shown in fig. 7.
Further, the diameter of a welding wire for welding is selected to be 1.2mm-1.6mm, the light spot width is 2.5mm-3.5mm, and the welding speed is 30mm/min-40mm/min; specifically, the diameter of the welding wire for butt welding should be 1.6mm in this embodiment, the spot width is 3.5mm, and the welding speed is 40mm/min; the fillet welding wire diameter should be 1.2mm, the light plate width between 2.5-3mm, and the welding speed is 30mm/min.
Further, the smaller the diameter of the welding wire is, the worse the filling capability is, and the condition that two or more times of fusion welding are needed easily occurs in the welding process, so that the welding stress and deformation are improved, the larger the bending radius is caused by the overlarge diameter of the welding wire, and the wire cannot be automatically fed; the welding wire diameter in the range is selected to finish the filling of the welding seam at one time, so that the occurrence of welding defects caused by multiple times of welding is avoided; the light spot width is too large, and the laser energy is dispersed, so that the depth of a welding line is reduced, the light spot width is too small, and the laser energy is too concentrated, so that the depth of the welding line is too large, and the welding effect in an aluminum alloy material can be improved by using the light spot width; the welding speed can influence the welding width and the welding depth, the welding speed is too low, and gas or water molecules in the environment can enter a material in a molten state to form air holes, so that the welding quality is influenced; the welding speed is too high, the welding width and the welding depth are not up to standard, the butt joint of parts is unstable, and the connection of the parts is unstable, so that the welding quality can be effectively ensured by selecting the welding speed.
In an alternative embodiment, the component material of the light-conducting box is aluminum alloy 6061-T6 or aluminum alloy 5A06; in the step S2 or S4, the heat treatment mode is heating to 140-145 ℃ for 6061-T6 of aluminum alloy, preserving heat for 235-245 min, and discharging and air cooling; or heating the aluminum alloy 5A06 with a furnace, preserving heat for 1-1.5h at 310-330 ℃, discharging and air-cooling after the heat preservation is finished; the heat preservation temperature is too low or/and the heat preservation time is too short, the welding stress cannot be released or is insufficiently released, and the effect of removing the welding stress cannot be achieved; the metal phase of the material is changed due to the over high heat preservation temperature, so that the performance of the material is affected; the long heat preservation time can increase the production cost.
The invention is not limited to the specific embodiments described above. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification, as well as to any novel one, or any novel combination, of the steps of the method or process disclosed.
Claims (8)
1. A splice welding process of a light-conducting box is characterized in that: the materials of the parts of the light conduction box are all aluminum alloy 6061-T6 or aluminum alloy 5A06; the light conduction box comprises a bottom plate (1) and a top plate (5), wherein an inclined support (2) for installing a reflector assembly is welded on the bottom plate (1), one end of the inclined support (2) is welded with the bottom plate (1), and the other end of the inclined support (2) is welded with a rear frame (6); both sides of the inclined support piece (2) are welded on the left side plate (8) and the right side plate (3) respectively; a front frame (4) is welded on the bottom plate (1); the rear frame (6), the front frame (4), the left side plate (8) and the right side plate (3), the bottom plate (1) and the top plate (5) are welded in pairs; the method comprises the following steps:
s1: welding parts; prefabricating and butting a bottom plate (1), an inclined support piece (2), a rear frame (6), a left side plate (8) and a right side plate (3), and welding and fixing every two prefabricated and butted parts to form a semi-finished product piece; the prefabricated butt joint is to perform prefabricated butt joint on each part by using pins, and normal-temperature curing resin glue is coated on a butt joint combination interface;
s2: performing first heat treatment; performing primary heat treatment on the semi-finished product by adopting a heat treatment mode to eliminate welding stress; if the material of the part is aluminum alloy 6061-T6, heating to 140-145 ℃, preserving heat for 235-245 min, and discharging and air cooling; if the part material is aluminum alloy 5A06, heating along with the furnace, preserving heat for 1-1.5h at 310-330 ℃, discharging from the furnace and air cooling after the heat preservation is finished;
s3: welding; prefabricating a butt-joint front frame (4) and a top plate (5) on the basis of the semi-finished product after heat treatment, and then welding the front frame (4) and the top plate (5) to form a light-conducting box;
s4: and performing secondary heat treatment on the light conduction box in a heat treatment mode to eliminate welding stress.
2. The splice welding process of light-conducting boxes according to claim 1, characterized in that: before proceeding to step S1, the individual parts need to be cleaned.
3. The splice welding process of light-conducting boxes according to claim 1, characterized in that: after step S2 is completed, step S21 is performed: correcting the shape; and (5) performing shape correction on the semi-finished product according to the data requirements.
4. A splice welding process for a light-conducting box according to claim 3, wherein: after step S21 is completed, a support (7) for supporting the mirror assembly is mounted on the diagonal support (2).
5. The splice welding process of light-conducting boxes according to claim 4, wherein: after the supporting piece (7) is installed, the installation standard and the supporting surface of the reflecting mirror component of the supporting piece (7) are subjected to a number milling.
6. The splice welding process of light-conducting boxes according to claim 1, characterized in that: in step S1 and step S3, laser welding is used as the welding method.
7. The splice welding process of light-conducting boxes according to claim 1, characterized in that: and after the prefabricated butting step is finished, welding between the parts is finished within 3 hours.
8. The splice welding process of light-conducting boxes according to claim 1, characterized in that: in step S1 and step S3, the type of welding at the time of the butt joint of the parts is any one of symmetrical fillet welding, symmetrical butt welding, and asymmetrical compound welding.
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