CN116275909A - Manufacturing method of heavy round square variable diameter node - Google Patents
Manufacturing method of heavy round square variable diameter node Download PDFInfo
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Abstract
The invention provides a manufacturing method of a heavy-duty round-square variable-diameter node, and relates to the technical field of building construction. The manufacturing flow system of the heavy round square reducing node comprises Tekla integrated modeling, wherein the Tekla integrated modeling is connected with a segment sectional plan, the segment sectional plan is connected with a part plate lofting and unfolding, the part plate lofting and unfolding is connected with part plate blanking, the part plate blanking is connected with groove cutting, the groove cutting is connected with a drawing bending line, and the drawing bending line is connected with a pressing segment; the pressing section is connected with a node group pair, the node group pair is connected with a pre-welding correction type, the pre-welding correction type is connected with welding, the welding is connected with a repair welding anti-cracking hole, the repair welding anti-cracking hole is connected with post-welding axis degree adjustment, and the post-welding axis degree adjustment is connected with nondestructive testing. The manufacturing method of the heavy-duty round variable-diameter node has higher stability and larger quality guarantee in the aspect of connecting the heavy-duty round variable-diameter node.
Description
Technical Field
The invention relates to the technical field of building construction, in particular to a manufacturing method of a heavy-duty round square variable-diameter node.
Background
Along with the rapid development of domestic steel structures, more and more super high-rise structures and special modeling structures preferentially select the steel structures as main structural forms, and structural designers often select the form of pouring concrete in steel pipe columns to realize steel-concrete structure optimization. Because the structural characteristics are that each load of the lower structure is larger, a steel pipe column with a larger section is required to be selected; the smaller section steel pipe column can meet the structural stress requirement along with the load reduction. The construction designer, for perfect utilization of the construction space and cost control of engineering by construction units, has a situation that the larger section steel pipe column changes to the smaller section steel pipe column, and the reducing node is generated accordingly.
For example: the Shanxi building and throwing business center western tower project is a mountain and western province major project and a dragon city new region landmark building, and comprises 3 layers underground, 41 layers on the ground, the building height is 184 meters, the structural form is an outer frame and core tube structure, the outer frame size is 46.2 x 46.2 meters, and the total amount of the steel structure is about 1.5 ten thousand tons. The 8 th layer on the western tower floor adopts a round square reducing node (see figure 1) at the elevation of 33.700 m on the upper part of the conversion truss layer, commonly called as a round sky and square earth, plays an important role in round square reducing conversion section, and is the part with the greatest manufacturing difficulty in the whole structure. The material of the dome-shaped node is Q390GJC, the upper circular section is phi 1200mm, the lower square section is 1350 x 1350mm, the node length is 3m, the plate thickness is 60mm, and the thickness is far higher than that of a common dome-shaped node, so that the manufacturing and forming or precision control are all very challenging.
Based on the above cases, there are the following problems:
(1) The length of the round square reducing node is 3m, the plate thickness is 60mm, the diameter and the side length of the upper and lower sections are both more than 1m, the design material is Q390GJC, and the processing and forming difficulties are extremely high;
(2) The welding operation space of the welding line inside the component is narrow, and the difficulty of ensuring the welding quality is high;
(3) The lower part of the round square reducing node is provided with a special-shaped conversion truss, the upper part of the round square reducing node is provided with a giant round pipe column, the round square and the round square are provided with important functions of round square section conversion, the whole node is inclined in space, the control difficulty of the manufacturing precision is high, and the machining precision can meet the field installation requirement without adopting effective technical measures.
Disclosure of Invention
(one) solving the technical problems
Aiming at the defects of the prior art, the invention provides a manufacturing method of a heavy-duty round-square variable-diameter node, which solves the problems of high difficulty in solving the existing round-square variable-diameter node and poor quality of the whole structure.
(II) technical scheme
In order to achieve the above purpose, the invention is realized by the following technical scheme: the manufacturing flow system of the heavy-duty round square reducing node comprises a Tekla integrated modeling, wherein the Tekla integrated modeling is connected with a segment sectional plan, the segment sectional plan is connected with a part plate lofting and unfolding, the part plate lofting and unfolding are connected with part plate blanking, the part plate blanking is connected with groove cutting, the groove cutting is connected with a drawing bending line, and the drawing bending line is connected with a pressing segment;
the pressing section is connected with a node group pair, the node group pair is connected with a pre-welding correction type, the pre-welding correction type is connected with welding, the welding is connected with a repair welding anti-cracking hole, the repair welding anti-cracking hole is connected with post-welding axis degree adjustment, and the post-welding axis degree adjustment is connected with nondestructive testing.
The key method for manufacturing the key points of the heavy-duty round square variable-diameter node specifically comprises the following key points:
s1, accurate modeling
1 based on the Tekla software global command: 1 proportion integral parametric modeling, wherein the node combines structural appearance design and stress requirement, adopts non-eccentric circular square diameter-changing design, uses split instructions to segment after integral parametric modeling is completed, and then spreads the segments through software plug-ins;
s2, sectional planning
After modeling, carrying out sectional planning by using a unit board simulation development technology, and selecting a 2-section splitting method to process and manufacture the node after analyzing 8 sections, 4 sections and 2 sections;
s3, finite element analysis
Carrying out Welding simulation contrast analysis on nodes by a 2-section splitting method and a 4-section splitting method through finite element software simulation Welding, and finally selecting the 2-section splitting method, namely a segmentation method for dividing a component into two parts by using the center line of the side of a square end plate so as to ensure the forming precision;
s4, arc plate pressing
And a 6000T large-tonnage hydraulic forming machine is selected for pressing, and the pressing is performed according to a bending line drawn in advance during pressing.
Preferably, after the BIM model in the step S3 is segmented, the curved surface is unfolded and lofted into a plane by using AutoCAD software, typesetting and blanking are carried out, after the blanking is finished, a K-shaped groove is formed at the butt joint position of the two sides of the dome and the space by using a flame cutting trolley, and a single V35-degree groove is formed at the side connected with the lower column.
Preferably, in the step S4, cracks may be generated at the square port in the pressing process due to repeated pressing, and after the bending is completed for 24 hours, a magnetic powder inspection method is adopted to detect the crack defects.
The welding process of the heavy-duty round-square reducing node specifically comprises the following steps of:
a. material tool preparation
Preparing a welding device: gas shield welding machine and submerged arc welding machine; auxiliary tool: the device comprises an angle grinder, a carbon rod, a flame baking gun, a tape measure, a feeler gauge, a welding seam gauge, an infrared thermometer, heat-insulating cotton, a strong light flashlight and an ultrasonic flaw detector; welding material: the gas shielded welding solid welding wire adopts phi 1.2ER50-6, the flux-cored wire adopts phi 1.2E501T-1, the submerged arc welding adopts phi 4.0H10Mn2 welding wire to match with SJ101 flux;
b. part plate blanking
When the parts plates of the dome are fed, each part plate is reserved with a welding seam shrinkage allowance of 1.5mm on the opposite sides of the two sides of the parts plates, an asymmetric K-shaped groove is formed on the assembly side of a dome node, a blunt side of 4mm is reserved for assembly and positioning, an X-shaped joint is formed after assembly, the side angle of a deep groove is set to be 20 degrees, and the side angle of a shallow groove is set to be 25 degrees;
c. pre-welding arrangement
Firstly polishing the groove position to obtain metallic luster, wherein oxide skin, rust, greasy dirt and water impurities are not needed on the surface of a base material to be welded and within a range of 30mm from the edge of the groove, preheating two sides of the groove by using a flame baking gun, wherein the preheating temperature of a Q390GJC material 60mm thick steel plate before welding is not lower than 80 ℃, the width of a preheating area is not smaller than 100mm, an arc striking plate and an arc extinguishing plate are additionally arranged at the end part of the welding line, the materials and the groove forms of the arc striking plate and the arc extinguishing plate are the same as those of the base material, when arc breaking occurs during welding, the arc breaking position is polished into a slope shape, and then arc striking welding is carried out after the arc striking plate is lapped, a lap joint is polished to a gentle transition, the spot welding is carried out by using gas to ensure that the spot welding line is flat, the spot welding line is free of defect, the length is 20-30 mm, and the spot welding line interval is 200-300 mm;
d. suspension or welding
After the welding is suspended or finished, heat-insulating cotton is covered on the surface of the welding line to achieve the effect of heat preservation and slow cooling, wherein the K-shaped groove is subjected to deep groove measurement to finish partial welding line welding, then shallow groove welding line welding is performed, the number of times of alternate symmetrical welding is increased, the welding deformation is observed in real time, and contralateral welding is performed in time to control welding deformation.
Preferably, in the step c, the formal welding seam adopts a gas shielded welding backing, back gouging of a carbon arc, submerged arc welding is carried out in a filling cover surface mode, the welding strictly conforms to the principle of multi-layer multi-pass welding, the phenomenon that the welding seam is cracked due to the increase of the restraint stress of the welding seam is avoided, the single-pass width of the gas shielded welding seam is not more than 20mm, a wind shovel is used for slag removal, particularly slag at dead angles is used after the welding of each layer of welding seam is completed, a U-shaped groove with a side face angle not smaller than 10 DEG is formed by gouging after back gouging, the surface of the gouged groove is polished by using a grinding wheel, and the welding is carried out after a carburization hardening layer and residual slag are removed.
The special-shaped round square reducing structure precision control scheme specifically comprises the following scheme:
1) Determining control points and dimensions
Firstly, determining and marking key control points and key dimensions through model analysis software, taking an end face without a bevel as a scribing reference, changing the position of a measuring point from an end part to a position 100mm inward from the end part, and generating a pre-welding assembly self-checking sheet according to theoretical coordinates of a component;
2) Coordinate measurement
The measurement is carried out on the assembled jig frame, the target position cannot vibrate in the measurement process, and then the position of the front measuring station and the rear measuring station are measured to obtain the coordinate value of the scanning point;
3) Pre-weld inspection
When the total station is used for carrying out detection before welding together with measurement software after the assembly is completed, a reflector plate is placed at a measurement point for scanning during measurement, the position with larger deviation is required to be readjusted and then welded, retesting is carried out after the welding is finished, a measurement result is imported into precision analysis software, point coordinates corresponding to a design model are compared, physical coordinates of a component and coordinates of a Tekla model are compared, and whether the overall size, the section square degree and the roundness meet the requirement of allowable deviation is checked;
4) Virtual pre-assembly
And (3) performing virtual pre-assembly on the scanning data integration of the segmented components by using simulation pre-assembly software, checking the overall accuracy of the components, and if the pre-assembly result is not large in deviation, adopting flame and mechanical pressure correction means to correct and measure the standard, and then performing the next process, wherein if the size is out of tolerance and difficult to correct, the measurement result can assist technicians to formulate a processing scheme after the size is out of tolerance.
(III) beneficial effects
The invention provides a manufacturing method of a heavy-duty round-square variable-diameter node. The beneficial effects are as follows:
the invention provides a manufacturing method of a heavy-duty round-square variable-diameter node, which explains the key technology of manufacturing and precision control of the heavy-duty round-square variable-diameter node in detail, combines cases to enable the node size and plate thickness to be reasonably segmented and pressed, reduces the segmentation number of the round-square-diameter node from 8 segments to 2 segments, reduces the welding seam number from 8 segments to 2 segments, better controls the welding shrinkage and deformation of the node, avoids the phenomenon of staggered stress concentration of the welding seam, and reasonably utilizes a digital detection means through a mature welding scheme and a careful precision control technology, finally smoothly ensures the construction period node progress and the product precision quality, obtains good social and economic benefits, and ensures that the round-square variable-diameter node is connected with high stability and has larger guarantee.
Drawings
FIG. 1 is a schematic flow chart of a manufacturing system of the present invention;
FIG. 2 is a schematic axial side view of a node connection of the present invention;
FIG. 3 is a schematic view of a round square reducer node of the invention;
FIG. 4 is a schematic diagram of a TEKLA "space-sky" overall parametric modeling input interface of the present invention;
FIG. 5 is a schematic diagram of a segmentation method according to the present invention;
FIG. 6 is a graph showing the comparison of the maximum plastic strain curves of the present invention in different segments;
FIG. 7 is a graph showing the comparison of equivalent stresses in different segments according to the present invention;
FIG. 8 is a graph showing the comparison of the maximum principal stresses of different segmentation methods according to the present invention;
FIG. 9 is a layout of a curved surface layout and parts of the present invention;
FIG. 10 is a bend line marking diagram of the present invention;
FIG. 11 is a press sequence diagram of the present invention;
FIG. 12 is a drawing of the balance of the part plate and groove labels of the present invention;
FIG. 13 is a table of reference welding process parameters according to the present invention;
FIG. 14 is a schematic view of two station position measurements according to the present invention;
FIG. 15 is a coordinate fitting diagram of a single component of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Examples:
1-15, the embodiment of the invention provides a manufacturing flow system of a heavy-duty round square reducing node, which comprises a Tekla integrated modeling, wherein the Tekla integrated modeling is connected with a segment segmentation plan, the segment segmentation plan is connected with a part plate lofting and unfolding, the part plate lofting and unfolding are connected with part plate blanking, the part plate blanking is connected with groove cutting, the groove cutting is connected with a drawing bending line, and the drawing bending line is connected with a pressing segment;
the pressing section is connected with a node assembly, the node assembly is connected with a welding front correction type, the welding front correction type is connected with welding, the welding connection is provided with a repair welding anti-cracking hole, the repair welding anti-cracking hole is connected with post-welding axis degree adjustment, and the post-welding axis degree adjustment is connected with nondestructive testing.
The key method for manufacturing the key points of the heavy-duty round square variable-diameter node specifically comprises the following key points:
s1, accurate modeling
1 based on the Tekla software global command: 1 proportion overall parametric modeling (see figure 4), wherein the modeling needs to consider an upper circular diameter parameter d, a lower square width parameter Rb, a length parameter Rh and a thickness parameter t of a node, and the modeling is divided into four types of square width direction eccentric ye, square length direction eccentric ze, double-sided eccentric and non-eccentric aiming at the condition of circular diameter change;
s2, sectional planning
After modeling, carrying out sectional planning by a unit plate simulation unfolding technology, and then selecting a 2-section splitting method for processing and manufacturing the node after analyzing 8 sections, 4 sections and 2 sections, wherein the common sectional mode of the dome in the industry is the 8-section splitting method (see figure 5), namely the sectional mode is split into 4 arc conical surfaces and 4 triangular planes, 8 butt welding seams can be generated in the sectional mode, the phenomenon of welding seam crossing can be generated, the stress concentration and correction of the node are difficult, the thickness of the node plate in the project is 60mm, the welding quantity is large, and the structural quality and the precision of a product cannot be ensured by adopting the traditional sectional method; if the joint is manufactured by a 4-section splitting method (see fig. 5), the total number of joints is reduced, but the number of splicing joints at the sections of the two ends is still 4, so that whether the joint can be manufactured by a 2-section splitting method (see fig. 5) can be considered;
s3, finite element analysis
The Welding simulation comparison analysis is carried out on the nodes by the 2-section splitting method and the 4-section splitting method through finite element software simulation Welding, so that the fact that the equivalent shaping strain of the dome-shaped space structure under the 4-section splitting method is larger can be seen (see fig. 6), obvious stress concentration phenomenon exists (see fig. 7 and 8), particularly, the stress value at the junction of the upper port, the lower port and the longitudinal weld joint is larger, the section size of the two end faces is difficult to ensure when the first-stage full penetration weld joint is welded by combining the thickness specification of the node, and therefore, the 2-section splitting method is finally selected, namely, the segmentation method of dividing the component into two parts by the side center line of the square end plate is adopted to ensure the shaping precision. After the segmentation of the BIM model is finished, the curved surface is unfolded and lofted into a plane by using AutoCAD software, typesetting and blanking are carried out, after the blanking is finished, K-shaped grooves are formed at the butt joint positions of the two sides of the dome by using a flame cutting trolley, and single V35-degree grooves are formed at the connection sides of the flame cutting trolley and the lower column;
the round-square transition curved surface can be formed by multi-position pressing, bending lines are marked according to a blanking unfolding diagram before pressing, and a calculation formula of the space between round pressing lines is adopted [1] The pressing interval can be obtained as follows: b=1.2t=1.2x60=72 mm (t is plate thickness), since the "2-stage splitting method" is adopted, in combination with the upper arc diameter r=1193 mm, the arc length of the segmented portion is divided by the pressing pitch: pi × D × 2 × 72 = 26.027222, i.e. the circular arc is divided into 26 segments at equal intervals, so the pressing line is divided into two segments at the upper circular arc side by 72mm as the interval, and the square end face corner is used as the end point, and the two segments are divided into two segments at the circular arc side center line according to radial conicity, as shown in fig. 10;
after the bending line is drawn, the transitional curved surface can lead to denser square side bending line when being bent, and the square end face side angle point is subjected to repeated pressing, so as to avoid cracking of the base material caused by external force, and the anti-cracking hole with phi 80mm is pre-drilled before bending, thereby achieving the purpose of releasing internal stress and effectively avoiding the generation of cracks. After finishing the correction, filling and plugging the anti-cracking hole by using welding material deposited metal (welding wire model ER 50-6), preheating a region to be welded at 110-130 ℃ according to the requirement of steel structure welding Specification GB50661 before welding (30-50 ℃ higher than the preheating temperature of normal welding under the same condition), and then performing welding;
s4, arc plate pressing
Because the node adopts thicker high-strength steel as a base material, a 6000T large-tonnage hydraulic forming machine is selected for pressing, and the bending lines are pressed according to the bending lines drawn in advance during pressing, each bending line is uniformly pressed for a plurality of times, and the ports are compared by using segment arc clamping templates which are prepared in advance, so that the situation of difficult assembly caused by partial uneven pressing phenomena such as overpressure is avoided, and the radian is ensured to reach the design value requirement. As shown in fig. 11, in the assembly process, since the sections are in a shape of a letter "C", in order to prevent the workpiece from colliding with the mold of the forming machine in the pressing process, a preliminary shape is formed by adopting a pressing sequence from two sides to the middle (see fig. 11), the two sections of the letter "C" are assembled and then shaped by using a 1500T hydraulic press, and after detection by a test plate, the two sections are fixed by using a support, and then are welded by a spliced weld;
and (3) in the pressing process, cracks may be generated at the square port due to repeated pressing, after bending is completed for 24 hours, performing crack defect detection by adopting a magnetic powder inspection method, if the position range and depth are determined firstly after the cracks are found, removing the cracks and the intact parent metals with 50mm lengths at the two ends of the cracks by using a carbon arc gouging machine, and after repair welding is completed and the surface is finished, determining whether the cracks are thoroughly removed by adopting a magnetic powder inspection method again, and judging whether repair welding is needed again.
The welding process of the heavy-duty round-square reducing node specifically comprises the following steps of:
a. material tool preparation
Preparing a welding device: gas shield welding machine and submerged arc welding machine; auxiliary tool: the device comprises an angle grinder, a carbon rod, a flame baking gun, a tape measure, a feeler gauge, a welding seam gauge, an infrared thermometer, heat-insulating cotton, a strong light flashlight and an ultrasonic flaw detector; welding material: the gas shielded welding solid welding wire adopts phi 1.2ER50-6, the flux-cored wire adopts phi 1.2E501T-1, the submerged arc welding adopts phi 4.0H10Mn2 welding wire to match with SJ101 flux;
b. part plate blanking
As shown in fig. 12, when the parts plates of the dome are blanked, each part plate is reserved with a 1.5mm welding seam shrinkage allowance on the opposite sides (width direction) of each part plate, so as to avoid that after the parts plates are welded, the section size of a node exceeds negative deviation, so that the on-site connection position is misplaced, an asymmetric K-shaped groove is formed on the assembly side of the dome, 4mm blunt edges are reserved for assembly and positioning, an X-shaped joint is formed after assembly, and because the gap of the X-shaped joint is smaller, the thickness of the steel plate of the node is larger, the welding gun is prevented from being difficult to extend into the root of the joint, the gas protection performance is prevented from being reduced due to longer dry extension, the welding seam quality is influenced, the angle of the side of the deep groove is set to be 20 DEG, and the filling quantity of grooves on the upper side and the lower side of the K-shaped groove is more beneficial to control the welding seam deformation in consideration of balancing as much as possible, and the angle of the side of the shallow groove is set to be 25 DEG;
c. pre-welding arrangement
Firstly polishing the groove position to obtain metallic luster before welding, wherein oxide skin, rust, greasy dirt and water impurities cannot exist on the surface of a base material to be welded and within a range of 30mm from the edge of the groove, and preheating two sides of the groove by using a flame baking gun, wherein the preheating temperature before welding of a Q390GJC 60mm thick steel plate cannot be lower than 80 ℃, the width of a preheating area cannot be smaller than 100mm, an arc striking plate and an arc extinguishing plate are additionally arranged at the end part of a welding line, the materials and the groove forms of the arc striking plate and the arc extinguishing plate are the same as those of the base material, and the length, the width and the thickness of the arc striking plate and the groove form are as follows: 150X 80X 60mm, when arc breakage occurs during welding, the arc breakage part is ground into a slope shape, the slope shape is lapped for 50mm, arc striking welding is performed, the lap joint is ground to smooth transition after welding, gas shielded welding is used for spot welding, the spot welding weld is flat, symmetrical and defect-free, the length is 20-30 mm, the spot welding weld is distributed symmetrically at 200-300 mm intervals, the formal weld adopts gas shielded welding bottoming, back gouging of a carbon arc gouging is performed, the welding is performed in a mode of filling the cover surface of submerged arc welding, the welding strictly conforms to the principle of multi-layer multi-channel welding, the weld cracking caused by the increase of the restraint stress is prevented, wherein the single-channel width of the gas shielded welding is not more than 20mm, a wind shovel is used for slag removal after each layer of weld is welded, particularly slag at dead corners is used, a U-shaped groove with a side angle of not less than 10 DEG is formed by using a grinding wheel for slag grinding the surface of the gouging, and the carburized hard layer and residual slag is removed for welding;
d. suspension or welding
After the welding is suspended or finished, heat-insulating cotton is covered on the surface of the welding line to achieve the effect of heat preservation and slow cooling, wherein the K-shaped groove is subjected to deep groove measurement to finish partial welding line welding, then shallow groove welding line welding is performed, the number of times of alternate symmetrical welding is increased, the welding deformation is observed in real time, and contralateral welding is performed in time to control welding deformation.
The welder is equipped with an infrared thermometer, strictly controls the temperature between roads, immediately stops welding when the temperature between roads exceeds 250 ℃, uses heat preservation cotton to cover slow cooling, continues welding when the temperature is reduced to be not lower than the preheating temperature, gouges back to be thorough when gouging back, uses a grinding wheel to polish the gouged surface, removes a carburized hardening layer, assembles the welding seam into a first-stage full penetration welding seam, does not allow the welding seam to have the defects of unwelded full, root shrinkage, undercut, arc scratch, poor joint, surface air holes and surface slag inclusion, and carries out 100% nondestructive inspection after 24 hours after welding.
The special-shaped round square reducing structure precision control scheme specifically comprises the following scheme:
because the round square reducing node is of a special-shaped structure, the forming is difficult, the component precision is difficult to guarantee, and the node precision is difficult to effectively and intuitively analyze through common pull rule inspection, so that in order to ensure that the planeness, the parallelism, the regularity and the node central axis deviation degree of the round square and square node round mouth end face and square mouth end face meet standard requirements, the precision control work of the node is carried out by adopting a digital detection analysis technology based on a total station.
1) Determining control points and dimensions
Firstly, determining and marking key control points and key dimensions through model analysis software, wherein a groove is often required to be formed at a site connection part, the position of a measuring point is difficult to reproduce, the end surface without the groove is required to be used as a marking reference, the position of the measuring point is required to be changed into a position with 100mm from the end part to the end part, and a pre-welding assembly self-checking sheet is generated according to theoretical coordinates of a component;
2) Coordinate measurement
As shown in fig. 3, the measurement is performed on the assembly jig frame to ensure that the point potential at the bottom of the component can be scanned, a coordinate system is established by setting at least two public targets before the measurement, the target position must not vibrate in the measurement process, and the measurement is performed through two front and rear station positions because of the large size of the component, and the two station positions can be scanned to the two public targets to obtain the coordinate value of the scanning point;
3) Pre-weld inspection
When the total station is used for carrying out detection before welding together with measurement software after the assembly is completed, a reflector plate is placed at a measurement point for scanning, the position with larger deviation is required to be readjusted and then welded, retest is carried out after the welding is finished, a measurement result is imported into precision analysis software (see figure 15), point coordinates corresponding to a design model are compared, physical coordinates of a component and Tekla model coordinates are compared, whether the overall size, the section square degree and the roundness meet the allowable deviation requirement is checked, and the novel measurement mode is a key technical means for realizing the measurement, analysis fitting and simulation pre-assembly of the special-shaped and heavy steel structure size;
4) Virtual pre-assembly
And (3) performing virtual pre-assembly on the scanning data integration of the segmented components by using simulation pre-assembly software, checking the overall accuracy of the components, and if the pre-assembly result is not large in deviation, adopting flame and mechanical pressure correction means to correct and measure the standard, and then performing the next process, wherein if the size is out of tolerance and difficult to correct, the measurement result can assist technicians to formulate a processing scheme after the size is out of tolerance.
The invention discloses a key technology for manufacturing and controlling precision of heavy round-square variable diameter nodes of a Shanxi construction and projection business center sitaglycone project. After reasonable segmentation and pressing planning are carried out by combining the size and the thickness of the joints, the segmentation number of the dome-shaped joints is reduced from 8 segments to 2 segments, and the number of welding seams is reduced from 8 segments to 2 segments, so that the shrinkage and deformation of the joint welding are better controlled, and the phenomenon of staggered stress concentration of the welding seams is avoided. And moreover, through a mature welding scheme and a careful precision control technology, a digital detection means is reasonably applied, so that the construction period node progress and the product precision quality are finally and smoothly ensured, and good social and economic benefits are obtained.
Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (7)
1. The utility model provides a heavy circle side reducing node's preparation flow system, includes Tekla integration modeling, its characterized in that: the Tekla integrated modeling is connected with a segment sectional planning, the segment sectional planning is connected with a part plate lofting and unfolding, the part plate lofting and unfolding is connected with part plate blanking, the part plate blanking is connected with groove cutting, the groove cutting is connected with a drawing bending line, and the drawing bending line is connected with a pressing section;
the pressing section is connected with a node group pair, the node group pair is connected with a pre-welding correction type, the pre-welding correction type is connected with welding, the welding is connected with a repair welding anti-cracking hole, the repair welding anti-cracking hole is connected with post-welding axis degree adjustment, and the post-welding axis degree adjustment is connected with nondestructive testing.
2. The key method for manufacturing the key points of the heavy-duty round square variable-diameter node is characterized by comprising the following specific points:
s1, accurate modeling
1 based on the Tekla software global command: 1 proportion integral parametric modeling, wherein the node combines structural appearance design and stress requirement, adopts non-eccentric circular square diameter-changing design, uses split instructions to segment after integral parametric modeling is completed, and then spreads the segments through software plug-ins;
s2, sectional planning
After modeling, carrying out sectional planning by using a unit board simulation development technology, and selecting a 2-section splitting method to process and manufacture the node after analyzing 8 sections, 4 sections and 2 sections;
s3, finite element analysis
Carrying out Welding simulation contrast analysis on nodes by a 2-section splitting method and a 4-section splitting method through finite element software simulation Welding, and finally selecting the 2-section splitting method, namely a segmentation method for dividing a component into two parts by using the center line of the side of a square end plate so as to ensure the forming precision;
s4, arc plate pressing
And a 6000T large-tonnage hydraulic forming machine is selected for pressing, and the pressing is performed according to a bending line drawn in advance during pressing.
3. The key method for manufacturing the key points of the heavy-duty round square variable-diameter node according to claim 2, which is characterized in that: and after the segmentation of the BIM in the step S3 is completed, the curved surface is unfolded and lofted into a plane by using AutoCAD software, typesetting and blanking are carried out, after the blanking is completed, a K-shaped groove is formed at the butt joint position of the two sides of the dome and the space by using a flame cutting trolley, and a single V35-degree groove is formed at the side connected with the lower column.
4. The key method for manufacturing the key points of the heavy-duty round square variable-diameter node according to claim 2, which is characterized in that: in the step S4, cracks may be generated at the square port in the pressing process due to repeated pressing, and after the bending is completed for 24 hours, the crack defect detection is performed by adopting a magnetic particle inspection method.
5. The welding process of the heavy-duty round square reducing node is characterized by comprising the following steps of:
a. material tool preparation
Preparing a welding device: gas shield welding machine and submerged arc welding machine; auxiliary tool: the device comprises an angle grinder, a carbon rod, a flame baking gun, a tape measure, a feeler gauge, a welding seam gauge, an infrared thermometer, heat-insulating cotton, a strong light flashlight and an ultrasonic flaw detector; welding material: the gas shielded welding solid welding wire adopts phi 1.2ER50-6, the flux-cored wire adopts phi 1.2E501T-1, the submerged arc welding adopts phi 4.0H10Mn2 welding wire to match with SJ101 flux;
b. part plate blanking
When the parts plates of the dome are fed, each part plate is reserved with a welding seam shrinkage allowance of 1.5mm on the opposite sides of the two sides of the parts plates, an asymmetric K-shaped groove is formed on the assembly side of a dome node, a blunt side of 4mm is reserved for assembly and positioning, an X-shaped joint is formed after assembly, the side angle of a deep groove is set to be 20 degrees, and the side angle of a shallow groove is set to be 25 degrees;
c. pre-welding arrangement
Firstly polishing the groove position to obtain metallic luster, wherein oxide skin, rust, greasy dirt and water impurities are not needed on the surface of a base material to be welded and within a range of 30mm from the edge of the groove, preheating two sides of the groove by using a flame baking gun, wherein the preheating temperature of a Q390GJC material 60mm thick steel plate before welding is not lower than 80 ℃, the width of a preheating area is not smaller than 100mm, an arc striking plate and an arc extinguishing plate are additionally arranged at the end part of the welding line, the materials and the groove forms of the arc striking plate and the arc extinguishing plate are the same as those of the base material, when arc breaking occurs during welding, the arc breaking position is polished into a slope shape, and then arc striking welding is carried out after the arc striking plate is lapped, a lap joint is polished to a gentle transition, the spot welding is carried out by using gas to ensure that the spot welding line is flat, the spot welding line is free of defect, the length is 20-30 mm, and the spot welding line interval is 200-300 mm;
d. suspension or welding
After the welding is suspended or finished, heat-insulating cotton is covered on the surface of the welding line to achieve the effect of heat preservation and slow cooling, wherein the K-shaped groove is subjected to deep groove measurement to finish partial welding line welding, then shallow groove welding line welding is performed, the number of times of alternate symmetrical welding is increased, the welding deformation is observed in real time, and contralateral welding is performed in time to control welding deformation.
6. The welding process of the heavy-duty round tapered node according to claim 5, wherein: in the step c, the formal welding seam adopts a mode of gas shielded welding bottoming, carbon arc gouging back gouging, submerged arc welding filling cover surface to weld, the welding strictly conforms to the principle of multi-layer multi-pass welding, the weld seam is prevented from being cracked due to the increase of the restraint stress of the welding seam, wherein the single-pass width of the gas shielded welding seam is not more than 20mm, a wind shovel is used for slag removal, particularly slag at dead angles is used after each layer of welding seam is welded, a U-shaped groove with a side surface angle not smaller than 10 DEG is formed by gouging after back gouging, a grinding wheel is used for polishing the gouged surface, and welding is performed after a carburization hardening layer and residual slag are removed.
7. The special-shaped round square reducing structure precision control scheme is characterized by comprising the following steps of:
1) Determining control points and dimensions
Firstly, determining and marking key control points and key dimensions through model analysis software, taking an end face without a bevel as a scribing reference, changing the position of a measuring point from an end part to a position 100mm inward from the end part, and generating a pre-welding assembly self-checking sheet according to theoretical coordinates of a component;
2) Coordinate measurement
The measurement is carried out on the assembled jig frame, the target position cannot vibrate in the measurement process, and then the position of the front measuring station and the rear measuring station are measured to obtain the coordinate value of the scanning point;
3) Pre-weld inspection
When the total station is used for carrying out detection before welding together with measurement software after the assembly is completed, a reflector plate is placed at a measurement point for scanning during measurement, the position with larger deviation is required to be readjusted and then welded, retesting is carried out after the welding is finished, a measurement result is imported into precision analysis software, point coordinates corresponding to a design model are compared, physical coordinates of a component and coordinates of a Tekla model are compared, and whether the overall size, the section square degree and the roundness meet the requirement of allowable deviation is checked;
4) Virtual pre-assembly
And (3) performing virtual pre-assembly on the scanning data integration of the segmented components by using simulation pre-assembly software, checking the overall accuracy of the components, and if the pre-assembly result is not large in deviation, adopting flame and mechanical pressure correction means to correct and measure the standard, and then performing the next process, wherein if the size is out of tolerance and difficult to correct, the measurement result can assist technicians to formulate a processing scheme after the size is out of tolerance.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117634003A (en) * | 2024-01-24 | 2024-03-01 | 上海建工（江苏）钢结构有限公司 | Tree-shaped conversion structure manufacturing method |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117634003A (en) * | 2024-01-24 | 2024-03-01 | 上海建工（江苏）钢结构有限公司 | Tree-shaped conversion structure manufacturing method |
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