CN118143574B - Roller repair welding method - Google Patents
Roller repair welding method Download PDFInfo
- Publication number
- CN118143574B CN118143574B CN202410583589.6A CN202410583589A CN118143574B CN 118143574 B CN118143574 B CN 118143574B CN 202410583589 A CN202410583589 A CN 202410583589A CN 118143574 B CN118143574 B CN 118143574B
- Authority
- CN
- China
- Prior art keywords
- roller
- welding
- repair
- flaw detection
- temperature
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 238000003466 welding Methods 0.000 title claims abstract description 128
- 238000000034 method Methods 0.000 title claims abstract description 86
- 230000008439 repair process Effects 0.000 title claims abstract description 74
- 230000007547 defect Effects 0.000 claims abstract description 96
- 238000001514 detection method Methods 0.000 claims abstract description 63
- 238000003754 machining Methods 0.000 claims abstract description 43
- 238000012545 processing Methods 0.000 claims abstract description 22
- 238000000227 grinding Methods 0.000 claims abstract description 16
- 238000005498 polishing Methods 0.000 claims abstract description 16
- 238000012544 monitoring process Methods 0.000 claims abstract description 11
- 238000004806 packaging method and process Methods 0.000 claims abstract description 10
- 238000004140 cleaning Methods 0.000 claims abstract description 8
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims abstract description 7
- 230000002265 prevention Effects 0.000 claims abstract description 7
- 238000007514 turning Methods 0.000 claims abstract description 7
- 238000012790 confirmation Methods 0.000 claims abstract 2
- 230000008569 process Effects 0.000 claims description 51
- 238000003801 milling Methods 0.000 claims description 20
- 230000008859 change Effects 0.000 claims description 18
- 238000010438 heat treatment Methods 0.000 claims description 18
- 238000007689 inspection Methods 0.000 claims description 10
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 6
- 238000012360 testing method Methods 0.000 claims description 6
- 239000000956 alloy Substances 0.000 claims description 3
- 229910045601 alloy Inorganic materials 0.000 claims description 3
- 238000004458 analytical method Methods 0.000 claims description 3
- 239000011248 coating agent Substances 0.000 claims description 3
- 238000000576 coating method Methods 0.000 claims description 3
- 238000004891 communication Methods 0.000 claims description 3
- 230000002950 deficient Effects 0.000 claims description 3
- 238000011010 flushing procedure Methods 0.000 claims description 3
- 239000004519 grease Substances 0.000 claims description 3
- 229910052759 nickel Inorganic materials 0.000 claims description 3
- 238000012858 packaging process Methods 0.000 claims description 3
- 238000007517 polishing process Methods 0.000 claims description 3
- 230000001681 protective effect Effects 0.000 claims description 3
- 238000007790 scraping Methods 0.000 claims description 3
- 238000002791 soaking Methods 0.000 claims description 3
- 239000004094 surface-active agent Substances 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 3
- 230000006872 improvement Effects 0.000 claims description 2
- 238000002360 preparation method Methods 0.000 claims description 2
- 230000000007 visual effect Effects 0.000 claims 1
- 238000012549 training Methods 0.000 abstract description 4
- 238000012800 visualization Methods 0.000 abstract description 2
- 230000005291 magnetic effect Effects 0.000 description 5
- 239000006247 magnetic powder Substances 0.000 description 3
- 230000035515 penetration Effects 0.000 description 3
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000004020 conductor Substances 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 230000000149 penetrating effect Effects 0.000 description 2
- 230000005855 radiation Effects 0.000 description 2
- 238000005496 tempering Methods 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000003814 drug Substances 0.000 description 1
- 230000005674 electromagnetic induction Effects 0.000 description 1
- 239000003302 ferromagnetic material Substances 0.000 description 1
- 238000005286 illumination Methods 0.000 description 1
- 239000012216 imaging agent Substances 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000003595 mist Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000002601 radiography Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 239000000523 sample Substances 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 238000011179 visual inspection Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Arc Welding In General (AREA)
Abstract
The invention discloses a roller repair welding method, which comprises the steps of roller cleaning, flaw detection, defect part machining removal, flaw detection confirmation, repair welding, polishing, flaw detection at repair welding, turning, grinding machine processing, integral flaw detection, rust prevention, packaging and the like. The invention avoids missing of defect detection through repeated flaw detection; carrying out standardized training on welder operation through infrared temperature field monitoring; by designing an accurate machining path coordinate curve, a plurality of work species can carry out accurate real-time data feedback, and various work species, in particular to a welding repair process, are standardized; under the support of a roller detection repair system, the method and the device carry out parameter visualization and operation standardization on the operation of each procedure, so that the processing and flaw detection are mutually verified in the whole repair process, the final result of roller repair performance detection is not required to be obtained, workshop products obtained by non-standard operation can be reworked in time, the risk of failure of repair and roller failure caused by multiple repair welding repair is avoided, and the repair cost is saved.
Description
Technical Field
The invention relates to the technical field of roller maintenance and repair, in particular to a roller repair welding method.
Background
As an important consumable part in a steel rolling line, the rolls are worn out for many reasons during use, so repair is an indispensable process. In order to prolong the service life of the roller, the roller which is in failure needs to be repaired again, various defects on the surface of the roller are eliminated, and the roller is repaired in time, so that unnecessary loss can be reduced after the roller obtains a good working state.
The detection method of the roller defect mainly comprises a plurality of penetration flaw detection (PT), magnetic powder flaw detection (MT), eddy current flaw detection (ET), radiographic inspection (RT), ultrasonic flaw detection (UT) and the like. The penetration flaw detection is also called as color flaw detection, and is mainly used for detecting open-type fatigue cracks, namely, a group of medicaments are used for cleaning the surface to be detected, penetrating agents are sprayed on the surface to be detected, after the penetration of the penetrating agents is finished, imaging agents are uniformly and thinly sprayed on the surface to be detected in a mist form, and crack judgment is carried out by visual inspection. The magnetic powder inspection is an effective inspection technology for defects such as open cracks and shallow inclusions, namely, after the ferromagnetic material is magnetized, magnetic lines of force on the surface and the near surface of a workpiece are locally distorted due to the existence of discontinuity to generate a leakage magnetic field (namely, a magnetic field formed when magnetic induction lines leave and enter the surface) to absorb magnetic powder applied to the surface of the workpiece, so that magnetic marks which are visible visually under proper illumination are formed, and the position, the shape and the size of the discontinuity are displayed. The eddy current flaw detection is a nondestructive flaw detection technology which utilizes an electromagnetic induction principle to induce eddy current on the surface of a metal piece by using an alternating current electromagnetic coil, namely when defects appear on the surface or near surface of a conductor, the strength and distribution of the eddy current are affected, the change of the eddy current causes the change of the voltage and the impedance of a detection coil, and the existence of the defects in the conductor can be indirectly known according to the change. The basic principle of the radiographic inspection is as follows: when the ray beam with uniform intensity is transmitted through an irradiated object, if defects or structural differences exist in local areas of the object, the attenuation of the object to rays is changed, so that the transmitted ray intensities of different parts are different, and then a certain detector (for example, a film is used in radiography) is used for detecting the transmitted ray intensities, so that the defects, the material distribution and the like in the object can be judged. The ultrasonic flaw detection is a method for detecting defects of parts by utilizing the characteristics that ultrasonic energy penetrates into the deep part of a metal material and is reflected at the boundary edge when entering another section from one section, reflected waves are respectively generated when ultrasonic beams are led into the metal from the surface of the part from a probe, defects and the bottom surface of the part are encountered, pulse waveforms are formed on a fluorescent screen, and the positions and the sizes of the defects are judged according to the pulse waveforms.
Common defects of the roller include cracks, slag inclusion, looseness and the like, and aiming at the roller with different failure modes, the roller cannot be simply ground and turned, and different repairing methods such as welding repair (including overlaying welding, laser welding and the like) are needed according to specific damage reasons. However, the existing roller repair welding process basically carries out repair according to personal experiences of welders, and the defect detection is different in standard, so that great hidden danger is brought to the production of subsequent repair products, and therefore, a set of standardized roller flaw detection and repair standards are urgently needed in the field.
Disclosure of Invention
The invention aims to solve the defects in the prior art and provides a roller repair welding method.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
A roller repair welding method comprises the following steps:
S1, cleaning a roller:
manually scraping grease, soaking in a surfactant builder tank for 30 minutes, and flushing with high-pressure water;
s2, flaw detection (PT+UT):
firstly, PT is used for measuring surface cracks, then UT is used for measuring internal defects, and the positions and the depths of defect marks I are made;
S3, machining to remove defect parts
The gantry machining center mills defective parts according to the flaw detection data of the defect mark I, and simultaneously considers the groove shape of the welding process and records the machining path;
S4, checking flaw detection (PT+UT):
Recording a processing mark II, measuring whether the surface has cracks or not by PT, measuring whether the surface has defects or not by UT, making the position and depth of the defect mark III if the defects exist, and then machining until the defects exist;
S5, welding repair:
carrying out multi-layer multi-pass welding on the repair part according to the processing mark II;
S6, polishing:
Firstly, a polishing sheet is used for rough grinding, polishing with a polishing sheet to facilitate flaw detection;
S7, flaw detection at the welding repair part:
PT is used for measuring whether the surface has cracks, UT is used for measuring whether the interior of the welding repair part has defects, if so, the positions and the depths of defect marks IV are made, and machining is performed until no defects exist;
S8, turning:
the roller heavy lathe carries out rough machining on the repaired part, and a 0.5MM allowance mill is reserved;
s9, grinding by a grinding machine:
grinding the roller grinder to the size according to the drawing size;
S10, overall flaw detection:
PT is used for measuring whether the surface has cracks, UT is used for measuring whether the interior of the welding repair part has defects, if so, the position and depth of a defect mark V are made, and machining is performed until no defects exist;
S11, rust prevention and packaging:
and (5) after the inspection is qualified, coating rust-proof oil, protecting the roller surface and packaging in a wooden box.
Preferably, the machining path is any one of a straight path, a circular arc path and a spiral path, so that the same depth machining along the defect is ensured as much as possible to ensure the uniformity of welding, and the stability of the welding process is facilitated, therefore, the milling cutter is not easy to change in depth during movement, namely the depth of the milling cutter is determined initially, and after feeding, the milling cutter is horizontally moved or the roller is rotated; the straight line path is along the axis direction of the roller, namely the roller does not rotate during processing, and the milling cutter is uniformly carried out along the axis direction of the roller to form the straight line path; the circular arc line path is along the circumferential direction of the roller, namely the position of the milling cutter is kept unchanged after feeding during processing, and the roller rotates at a constant speed to form the circular arc line path; the spiral path is the depth of the milling cutter is determined at the beginning, and after the milling cutter is fed, the milling cutter is horizontally moved at a constant speed and the roller is rotated at a constant speed, so that the spiral path is formed on the surface of the roller.
Preferably, the multi-layer multi-pass welding process includes the following steps:
① Local heating: heating to 500 ℃ by a shaft local heating furnace, wherein the temperature is close to the tempering temperature (500-550 ℃) of the roller, so that the toughness of the roller during welding can be ensured;
② Preheating welding wires: the nickel-based alloy welding wire (diameter chosen to be 1.2mm in this example) was preheated to 100 ℃;
③ Welding: the protective gas comprises 85% Ar and 15% He by volume percentage, the current is 120-150A, the wind prevention is noted, and the multilayer multi-pass welding is carried out;
④ And (3) roller temperature test: the temperature of the roller is measured in real time by welding, wherein the temperature of the welding part and the range near the welding part is required to be 300-350 ℃ between layers of the welding part;
⑤ Preserving heat for 5h: after welding, covering the welding part by a shaft local heating furnace, and keeping the temperature of the welding part at 450+/-50 ℃ for 5 hours;
⑥ Gradually cooling to room temperature, closing the shaft local heating furnace until the temperature of the welded part is lower than 300 ℃, then removing the shaft local heating furnace, and naturally cooling to room temperature.
Further, the ④ roller temperature test adopts an infrared thermal imager to visually observe the temperature change of the welding position, and the observation of the temperature change comprises real-time welding temperature of the working point of the welding position, a line temperature field of the welding position, the change of the line temperature field along with the welding processing time and the temperature change of radiation near the line temperature field.
Further, a series of temperature field pictures are shot through the infrared thermal imager, the temperature change in the welding process is summarized, and standard temperature field group pictures are obtained through analysis and summarization of a real operation welder and a welder expert, so that a reference is provided for subsequent roller repairing processing.
The roller repair welding method also applies a roller detection repair system, and the roller detection repair system comprises the following modules:
and the general control monitoring terminal: the system is provided with a special database for storing process parameters and operation data and providing standards for subsequent operation;
equipment workshop: the device comprises a cleaning room, a flaw detector, a gantry machining center, a welding and repairing machine, polishing equipment, a roller heavy lathe, a roller grinder, an antirust workshop and a packaging workshop;
And a process management platform: recording and comparing the defect mark I, the processing mark II, the defect mark III, the defect mark IV and the defect mark V, avoiding missing defects, and judging whether new defects are generated in the welding repair process; designing a new machining path through the defect mark I and the defect mark I recorded in the database history record and the reference of the corresponding machining path, and transmitting the new machining path to an equipment workshop for reference and feedback of operators; recording parameters and operations of a multi-layer multi-pass welding process, a polishing process, a turning process, a grinding machine process, an anti-rust process and a packaging process, importing the parameters and the operations into a database, and updating the parameters and the operations in the database in time;
Mobile terminal app: the method is used for displaying a process management interface and carrying out historical data calling, real-time data recording, operation feedback and workshop communication.
Preferably, the roller detection and repair system is used as follows:
The general control monitoring terminal is provided with a large display screen for displaying a process management platform and carrying out block management on each process; each process data in the process management platform is retrieved and controlled in real time through the mobile terminal app, new process parameters and operation data are input, and the new process parameters and operation data are fed back to the master control monitoring terminal; the general control monitoring terminal is communicated with each operator and the mobile terminal thereof in the equipment workshop, so that the operation of each equipment is monitored in real time, and compared with and recorded by historical data; comparing the performance of the final roller with a standard component, and calling data of each procedure, verifying the data and the rationality of operation, thereby carrying out operation improvement and preparation of standardized standards;
The method specifically comprises the following steps: designing a machining path according to the defect mark I obtained by the flaw detector, and feeding back to a gantry machining center; the gantry machining center returns to the flaw detector for reworking according to the machining mark II and the defect mark III, and feeds back to a welder when the defect mark III is not present, and after repair welding, parameters of a plurality of layers of welding procedures and welding cores are timely supplemented, and the parameters and the welding cores are compared according to welding quality and historical standard data; further recording and perfecting welding operation according to the defect mark IV; performing feedback of flaw detection operation according to the flaw mark V, and providing data for subsequent flaw detection standards; through repeated flaw detection and data feedback among a plurality of work types, omission of flaw detection is avoided, and especially, the defect coverage incompleteness caused by improper repair welding is avoided aiming at inspection of repair welding procedures, so that standardized training is carried out on welding operation in actual operation.
Further, in order to ensure the reliability of the repair data, an axis scale is arranged in the axial direction of the roller, a circumference scale is arranged in the circumferential direction of the roller, a coordinate curve of each machining path is obtained, and information feedback among all working procedures is facilitated.
Compared with the prior art, the invention has the beneficial effects that:
1. The invention avoids missing of defect detection through multiple flaw detection, especially aims at the inspection of a repair welding procedure, avoids incomplete coverage of defects caused by improper repair welding, and carries out standardized training on welding operation in actual operation through monitoring of an infrared temperature field.
2. By arranging a special roller detection and repair system and designing an accurate machining path coordinate curve, the invention can accurately feed back data among a plurality of work types in real time and standardize the welding repair process of each work type.
3. Under the support of a roller detection repair system, the method and the device carry out parameter visualization and operation standardization on the operation of each procedure, so that the processing and flaw detection are mutually verified in the whole repair process, the final result of roller repair performance detection is not required to be obtained, workshop products obtained by non-standard operation can be reworked in time, the risk of failure of repair and roller failure caused by multiple repair welding repair is avoided, and the repair cost is saved.
Drawings
Fig. 1 is a flowchart of a method for repairing a roll by repair welding according to 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.
Example 1:
referring to fig. 1, a method for repairing a roll by welding, comprising the steps of:
S1, cleaning a roller:
manually scraping grease, soaking in a surfactant builder tank for 30 minutes, and flushing with high-pressure water;
s2, flaw detection (PT+UT):
firstly, PT is used for measuring surface cracks, then UT is used for measuring internal defects, and the positions and the depths of defect marks I are made;
S3, machining to remove defect parts
The gantry machining center mills defective parts according to the flaw detection data of the defect mark I, and simultaneously considers the groove shape of the welding process and records the machining path;
S4, checking flaw detection (PT+UT):
Recording a processing mark II, measuring whether the surface has cracks or not by PT, measuring whether the surface has defects or not by UT, making the position and depth of the defect mark III if the defects exist, and then machining until the defects exist;
S5, welding repair:
carrying out multi-layer multi-pass welding on the repair part according to the processing mark II; the multi-layer multi-pass welding process comprises the following steps:
① Local heating: heating to 500 ℃ by a shaft local heating furnace, wherein the temperature is close to the tempering temperature (500-550 ℃) of the roller, so that the toughness of the roller during welding can be ensured;
② Preheating welding wires: the nickel-based alloy welding wire (diameter chosen to be 1.2mm in this example) was preheated to 100 ℃;
③ Welding: the protective gas comprises 85% Ar and 15% He by volume percentage, the current is 120-150A, the wind prevention is noted, and the multilayer multi-pass welding is carried out;
④ And (3) roller temperature test: the temperature of the roller is measured in real time by welding, wherein the temperature of the welding part and the range near the welding part is required to be 300-350 ℃ between layers of the welding part;
⑤ Preserving heat for 5h: after welding, covering the welding part by a shaft local heating furnace, and keeping the temperature of the welding part at 450+/-50 ℃ for 5 hours;
⑥ Gradually cooling to room temperature, closing the shaft local heating furnace until the temperature of the welded part is lower than 300 ℃, then removing the shaft local heating furnace, and naturally cooling to room temperature.
S6, polishing:
Firstly, a polishing sheet is used for rough grinding, polishing with a polishing sheet to facilitate flaw detection;
S7, flaw detection at the welding repair part:
PT is used for measuring whether the surface has cracks, UT is used for measuring whether the interior of the welding repair part has defects, if so, the positions and the depths of defect marks IV are made, and machining is performed until no defects exist;
S8, turning:
the roller heavy lathe carries out rough machining on the repaired part, and a 0.5MM allowance mill is reserved;
s9, grinding by a grinding machine:
grinding the roller grinder to the size according to the drawing size;
S10, overall flaw detection:
PT is used for measuring whether the surface has cracks, UT is used for measuring whether the interior of the welding repair part has defects, if so, the position and depth of a defect mark V are made, and machining is performed until no defects exist;
S11, rust prevention and packaging:
and (5) after the inspection is qualified, coating rust-proof oil, protecting the roller surface and packaging in a wooden box.
Example 2:
On the basis of the embodiment 1, as an operation standard of standardized machining, a machining path is designed to be any one of a straight path, a circular arc path and a spiral path according to a defect part, and to ensure welding uniformity, the same-depth machining along the defect part is ensured as much as possible, so that the stability of a welding process is facilitated, the depth upper milling cutter is not easy to change during movement, namely the depth of the milling cutter is determined initially, and after feeding, the milling cutter or a rotary roller is horizontally moved; the straight line path is along the axis direction of the roller, namely the roller does not rotate during processing, and the milling cutter is uniformly carried out along the axis direction of the roller to form the straight line path; the circular arc line path is along the circumferential direction of the roller, namely the position of the milling cutter is kept unchanged after feeding during processing, and the roller rotates at a constant speed to form the circular arc line path; the spiral path is the depth of the milling cutter is determined at the beginning, and after the milling cutter is fed, the milling cutter is horizontally moved at a constant speed and the roller is rotated at a constant speed, so that the spiral path is formed on the surface of the roller.
Example 3:
Based on the embodiment 1, in order to normalize the operation standard of the repair welding process, an infrared thermal imager is adopted in the ④ roller temperature test to visually observe the temperature change of the welding position, wherein the temperature change observation comprises real-time welding temperature of the working point of the welding position, a line temperature field of the welding position, the change of the line temperature field along with the welding process time and the temperature change of radiation near the line temperature field.
And a series of temperature field pictures are shot through the infrared thermal imager, the temperature change in the welding process is summarized, and standard temperature field group pictures are obtained through analysis and summarization of an actual welder and a welder expert, so that a reference is provided for the subsequent roller repairing processing.
Example 4:
on the basis of the embodiment 1, for normalizing the operation standard of the whole set of process, a roller detection and repair system is also applied, and the roller detection and repair system comprises the following modules:
and the general control monitoring terminal: the system is provided with a special database for storing process parameters and operation data and providing standards for subsequent operation;
equipment workshop: the device comprises a cleaning room, a flaw detector, a gantry machining center, a welding and repairing machine, polishing equipment, a roller heavy lathe, a roller grinder, an antirust workshop and a packaging workshop;
And a process management platform: recording and comparing the defect mark I, the processing mark II, the defect mark III, the defect mark IV and the defect mark V, avoiding missing defects, and judging whether new defects are generated in the welding repair process; designing a new machining path through the defect mark I and the defect mark I recorded in the database history record and the reference of the corresponding machining path, and transmitting the new machining path to an equipment workshop for reference and feedback of operators; recording parameters and operations of a multi-layer multi-pass welding process, a polishing process, a turning process, a grinding machine process, an anti-rust process and a packaging process, importing the parameters and the operations into a database, and updating the parameters and the operations in the database in time;
Mobile terminal app: the method is used for displaying a process management interface and carrying out historical data calling, real-time data recording, operation feedback and workshop communication.
The using process of the roller detection and repair system is as follows:
Designing a machining path according to the defect mark I obtained by the flaw detector, and feeding back to a gantry machining center; the gantry machining center returns to the flaw detector for reworking according to the machining mark II and the defect mark III, and feeds back to a welder when the defect mark III is not present, and after repair welding, parameters of a plurality of layers of welding procedures and welding cores are timely supplemented, and the parameters and the welding cores are compared according to welding quality and historical standard data; further recording and perfecting welding operation according to the defect mark IV; performing feedback of flaw detection operation according to the flaw mark V, and providing data for subsequent flaw detection standards; through repeated flaw detection and data feedback among a plurality of work types, omission of flaw detection is avoided, and especially, the defect coverage incompleteness caused by improper repair welding is avoided aiming at inspection of repair welding procedures, so that standardized training is carried out on welding operation in actual operation.
Example 5:
on the basis of embodiment 4, in order to ensure the reliability of the repair data transmission process, an axis scale is arranged in the axial direction of the roller, and a circumference scale is arranged in the circumferential direction of the roller, so that the coordinate curve of each machining path is obtained, and information feedback between each working procedure is facilitated.
The foregoing is only a preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art, who is within the scope of the present invention, should make equivalent substitutions or modifications according to the technical scheme of the present invention and the inventive concept thereof, and should be covered by the scope of the present invention.
Claims (6)
1. The roller repair welding method is characterized by comprising the following steps of:
S1, cleaning a roller:
manually scraping grease, soaking in a surfactant builder tank for 30 minutes, and flushing with high-pressure water;
S2, flaw detection:
firstly, PT is used for measuring surface cracks, then UT is used for measuring internal defects, and the positions and the depths of defect marks I are made;
S3, machining to remove defect parts
The gantry machining center mills defective parts according to the flaw detection data of the defect mark I, and simultaneously considers the groove shape of the welding process and records the machining path;
s4, flaw detection confirmation:
Recording a processing mark II, measuring whether the surface has cracks or not by PT, measuring whether the surface has defects or not by UT, making the position and depth of the defect mark III if the defects exist, and then machining until the defects exist;
S5, welding repair:
carrying out multi-layer multi-pass welding on the repair part according to the processing mark II;
S6, polishing:
Firstly, a polishing sheet is used for rough grinding, polishing with a polishing sheet to facilitate flaw detection;
S7, flaw detection at the welding repair part:
PT is used for measuring whether the surface has cracks, UT is used for measuring whether the interior of the welding repair part has defects, if so, the positions and the depths of defect marks IV are made, and machining is performed until no defects exist;
S8, turning:
the roller heavy lathe carries out rough machining on the repaired part, and a 0.5MM allowance mill is reserved;
s9, grinding by a grinding machine:
grinding the roller grinder to the size according to the drawing size;
S10, overall flaw detection:
PT is used for measuring whether the surface has cracks, UT is used for measuring whether the interior of the welding repair part has defects, if so, the position and depth of a defect mark V are made, and machining is performed until no defects exist;
S11, rust prevention and packaging:
after the inspection is qualified, coating rust-proof oil, protecting the roller surface and packaging in a wooden box;
The roller repair welding method also applies a roller detection repair system, and the roller detection repair system comprises the following modules:
and the general control monitoring terminal: the system is provided with a special database for storing process parameters and operation data and providing standards for subsequent operation;
equipment workshop: the device comprises a cleaning room, a flaw detector, a gantry machining center, a welding and repairing machine, polishing equipment, a roller heavy lathe, a roller grinder, an antirust workshop and a packaging workshop;
And a process management platform: recording and comparing the defect mark I, the processing mark II, the defect mark III, the defect mark IV and the defect mark V, avoiding missing defects, and judging whether new defects are generated in the welding repair process; designing a new machining path through the defect mark I and the defect mark I recorded in the database history record and the reference of the corresponding machining path, and transmitting the new machining path to an equipment workshop for reference and feedback of operators; recording parameters and operations of a multi-layer multi-pass welding process, a polishing process, a turning process, a grinding machine process, an anti-rust process and a packaging process, importing the parameters and the operations into a database, and updating the parameters and the operations in the database in time;
mobile terminal app: the system is used for displaying a process management interface and carrying out historical data calling, real-time data recording, operation feedback and workshop communication;
The using process of the roller detection and repair system is as follows:
The general control monitoring terminal is provided with a large display screen for displaying a process management platform and carrying out block management on each process; each process data in the process management platform is retrieved and controlled in real time through the mobile terminal app, new process parameters and operation data are input, and the new process parameters and operation data are fed back to the master control monitoring terminal; the general control monitoring terminal is communicated with each operator and the mobile terminal thereof in the equipment workshop, so that the operation of each equipment is monitored in real time, and compared with and recorded by historical data; and comparing the performance of the final roller with a standard component, and calling data of each procedure, verifying the data and the rationality of operation, thereby carrying out operation improvement and preparation of a standardized standard.
2. The method for repairing a welded roll according to claim 1, wherein the machining path is any one of a straight path, a circular arc path and a spiral path; the straight line path is along the axial direction of the roller, namely the roller does not rotate during processing, and the milling cutter is uniformly carried out along the axial direction of the roller to form the straight line path; the circular arc line path is along the circumferential direction of the roller, namely the position of the milling cutter is kept unchanged after feeding during processing, and the roller rotates at a constant speed to form the circular arc line path; the spiral path is determined by the depth of the milling cutter at the beginning, and after feeding, the milling cutter is horizontally moved at a constant speed and the roller is rotated at a constant speed, so that the spiral path is formed on the surface of the roller.
3. The method for repairing a welded roll according to claim 1, wherein the multi-layer and multi-pass welding process comprises the steps of:
① Local heating: heating to 500 ℃ by a shaft type local heating furnace;
② Preheating welding wires: preheating a nickel-based alloy welding wire to 100 ℃;
③ Welding: the protective gas comprises 85% Ar and 15% He by volume percentage, the current is 120-150A, the wind prevention is noted, and the multilayer multi-pass welding is carried out;
④ And (3) roller temperature test: the temperature of the roller is measured in real time by welding, wherein the temperature of the welding part and the range near the welding part is required to be 300-350 ℃ between layers of the welding part;
⑤ Preserving heat for 5h: after welding, covering the welding part by a shaft local heating furnace, and keeping the temperature of the welding part at 450+/-50 ℃ for 5 hours;
⑥ Gradually cooling to room temperature, closing the shaft local heating furnace until the temperature of the welded part is lower than 300 ℃, then removing the shaft local heating furnace, and naturally cooling to room temperature.
4. A method of repairing a roll by welding according to claim 3, wherein the ④ roll temperature test is performed by using a thermal infrared imager, and the visual observation of the temperature change of the welded part includes real-time welding temperature of the working point of the welded part, a line temperature field of the welded part, a change of the line temperature field with the welding time, and a change of the temperature radiated near the line temperature field.
5. The method for repairing welded roller according to claim 4, wherein a series of temperature field pictures are shot through an infrared thermal imager, temperature changes in the welding process are summarized, and standard temperature field group pictures are obtained through analysis and summarization of a real-time welder and a welder expert, so that reference is provided for subsequent roller repairing processing.
6. The method for repairing welded seam of roller according to claim 1, wherein in order to ensure the reliability of repairing data, an axis scale is arranged in the axial direction of the roller, and a circumference scale is arranged in the circumferential direction of the roller, so that the coordinate curve of each machining path is obtained, and information feedback between each working procedure is facilitated.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410583589.6A CN118143574B (en) | 2024-05-11 | 2024-05-11 | Roller repair welding method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410583589.6A CN118143574B (en) | 2024-05-11 | 2024-05-11 | Roller repair welding method |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN118143574A CN118143574A (en) | 2024-06-07 |
| CN118143574B true CN118143574B (en) | 2024-09-06 |
Family
ID=91301489
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202410583589.6A Active CN118143574B (en) | 2024-05-11 | 2024-05-11 | Roller repair welding method |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN118143574B (en) |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107111298A (en) * | 2014-10-31 | 2017-08-29 | 电子云工业4.0科技公司 | Method for optimizing computer numerically controlled machine machine process productivity ratio |
| CN110640298A (en) * | 2019-09-26 | 2020-01-03 | 沈阳航空航天大学 | Friction stir welding real-time temperature field monitoring system and control method |
| CN113199200A (en) * | 2021-05-25 | 2021-08-03 | 常州冶俊机械设备有限公司 | Laser cladding repair process for end chamfer and roll neck of supporting roll |
| CN116079332A (en) * | 2022-12-05 | 2023-05-09 | 北京首钢机电有限公司 | Repairing method for arc-shaped backing plate of bearing block assembly of lower supporting roller of rolling mill |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| RU2376164C1 (en) * | 2008-10-23 | 2009-12-20 | Открытое акционерное общество "Головной центр сервисного обслуживания и ремонта Концерна ПВО "Алмаз-Антей" "Гранит" | Method to repair sophisticated engineering systems and their interchangeable components using mobile repair-and-diagnostics complexes |
| CN106563898A (en) * | 2016-11-11 | 2017-04-19 | 南京理工大学 | Management system for digital welding workshop |
| CN107150158B (en) * | 2017-06-29 | 2019-08-09 | 中国科学院自动化研究所 | Blind area weld seam online evaluation and control system based on thermal infrared imager |
-
2024
- 2024-05-11 CN CN202410583589.6A patent/CN118143574B/en active Active
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107111298A (en) * | 2014-10-31 | 2017-08-29 | 电子云工业4.0科技公司 | Method for optimizing computer numerically controlled machine machine process productivity ratio |
| CN110640298A (en) * | 2019-09-26 | 2020-01-03 | 沈阳航空航天大学 | Friction stir welding real-time temperature field monitoring system and control method |
| CN113199200A (en) * | 2021-05-25 | 2021-08-03 | 常州冶俊机械设备有限公司 | Laser cladding repair process for end chamfer and roll neck of supporting roll |
| CN116079332A (en) * | 2022-12-05 | 2023-05-09 | 北京首钢机电有限公司 | Repairing method for arc-shaped backing plate of bearing block assembly of lower supporting roller of rolling mill |
Also Published As
| Publication number | Publication date |
|---|---|
| CN118143574A (en) | 2024-06-07 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN104786003B (en) | The restorative procedure of housing main bearing dead eye | |
| CN102756235B (en) | Field welding repair method especially for larger and penetrating defects in steel casting with heavy wall thickness | |
| CN104532233B (en) | Rotor axle position laser melting coating restorative procedure | |
| JP6437758B2 (en) | Inspection device for joint type outer joint member of constant velocity universal joint | |
| CN109909585A (en) | A kind of build-up welding repair method and system for the maintenance of stainless steel branch pipe weld seam | |
| CN114871620B (en) | Thick plate welding quality monitoring and control system and welding method thereof | |
| RU2639182C1 (en) | Method of repair of longitudinal pipe weld, applied by laser welding | |
| CA2822396C (en) | Re-manufacture and apparatus of worn railroad freight car and locomotive wheels by rotational continuous longitudinal welding | |
| CN106088572B (en) | Construction method is transformed and is used in turn to aluminum alloy mould plate | |
| CN113560701A (en) | Submerged arc welding operation step and method | |
| CN118143574B (en) | Roller repair welding method | |
| CN117758254A (en) | Laser cladding repair method and device for surface damage of part and part | |
| CN112008195A (en) | Research and development of construction process for controlling welding cracks of composite board | |
| CN108971883B (en) | Suitable for cheating the field repairing method of cavity space | |
| CN116329815A (en) | Wear-resistant surfacing method for annular high-temperature-resistant stainless steel and application thereof | |
| CN105817831A (en) | Threaded hole defect detecting and repairing method and device for large container and device of nuclear power plant | |
| CN114309645A (en) | Method for repairing turbine blade of gas turbine | |
| CN108048836A (en) | A kind of laser repair method of rolling mill bearing | |
| CN108165983A (en) | A kind of laser repair method of mobile cross head | |
| CN114378542A (en) | Method for manufacturing standard test block for nondestructive testing of crack defects | |
| CN103357988A (en) | Shaft precision machined part damage defect welding repair method | |
| CN112439973A (en) | Repair method for surfacing layer on sealing surface of Russian gate | |
| CN118417657B (en) | Automatic welding method for circular seams of thin-wall steel plate cylinders | |
| CN113458594B (en) | Welding method for nuclear main pump centering block laser deposited cobalt-based alloy powder | |
| CN115847000A (en) | Online repairing method for gear tooth surface damage in motor coupler of rolling mill production line |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| GR01 | Patent grant | ||
| GR01 | Patent grant |