CN111250824B - Repairing process for inner hole wear surface of upper beam of large hydraulic press - Google Patents
Repairing process for inner hole wear surface of upper beam of large hydraulic press Download PDFInfo
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- CN111250824B CN111250824B CN202010235664.1A CN202010235664A CN111250824B CN 111250824 B CN111250824 B CN 111250824B CN 202010235664 A CN202010235664 A CN 202010235664A CN 111250824 B CN111250824 B CN 111250824B
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- 238000000034 method Methods 0.000 title claims abstract description 29
- 238000003466 welding Methods 0.000 claims abstract description 203
- 238000010438 heat treatment Methods 0.000 claims abstract description 76
- 238000005299 abrasion Methods 0.000 claims abstract description 50
- 230000008439 repair process Effects 0.000 claims abstract description 21
- 238000004519 manufacturing process Methods 0.000 claims abstract description 15
- 241001669679 Eleotris Species 0.000 claims abstract description 8
- 229910000831 Steel Inorganic materials 0.000 claims description 24
- 239000010959 steel Substances 0.000 claims description 24
- 230000007547 defect Effects 0.000 claims description 18
- 239000011521 glass Substances 0.000 claims description 9
- 238000012545 processing Methods 0.000 claims description 8
- 238000003754 machining Methods 0.000 claims description 6
- 239000002893 slag Substances 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 5
- 238000007689 inspection Methods 0.000 claims description 5
- 238000004321 preservation Methods 0.000 claims description 5
- 238000009434 installation Methods 0.000 claims description 4
- 230000007774 longterm Effects 0.000 claims description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical group [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 3
- 244000137852 Petrea volubilis Species 0.000 claims description 3
- 239000010953 base metal Substances 0.000 claims description 3
- 230000005540 biological transmission Effects 0.000 claims description 3
- 229910052799 carbon Inorganic materials 0.000 claims description 3
- 238000005520 cutting process Methods 0.000 claims description 3
- 230000004927 fusion Effects 0.000 claims description 3
- 239000002932 luster Substances 0.000 claims description 3
- 238000012797 qualification Methods 0.000 claims description 3
- 238000012423 maintenance Methods 0.000 abstract description 3
- 239000010410 layer Substances 0.000 description 25
- 238000005096 rolling process Methods 0.000 description 8
- 230000000712 assembly Effects 0.000 description 2
- 238000000429 assembly Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 230000008642 heat stress Effects 0.000 description 2
- 230000033001 locomotion Effects 0.000 description 2
- 238000013461 design Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 230000001020 rhythmical effect Effects 0.000 description 1
- 230000035882 stress Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/0026—Arc welding or cutting specially adapted for particular articles or work
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/02—Seam welding; Backing means; Inserts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/235—Preliminary treatment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/32—Accessories
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- 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
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- Plasma & Fusion (AREA)
- Heat Treatment Of Articles (AREA)
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Abstract
The invention discloses a welding device for an inner hole wearing surface of an upper cross beam of a large-scale hydraulic press, which is characterized by comprising a bottom plate, a supporting seat, a sleeper, a welding gun and a central annular heating device; the center annular heating device is arranged in the center of the upper surface of the bottom plate, the supporting seats are arranged on the left side and the right side of the upper surface of the bottom plate in parallel, and sleepers are respectively arranged on each supporting seat; the welding gun is arranged at the central annular heating device. The invention also discloses a repairing process of the inner hole abrasion surface of the upper cross beam of the large-scale hydraulic press. The invention has the advantages of low investment cost, convenient field operation and maintenance, short repair time, greatly reduced production stopping time and production stopping loss, and the welded and repaired upper beam completely meets the service cycle of the large-scale hydraulic press, thereby greatly reducing the purchase cost of the upper beam of the large-scale hydraulic press.
Description
Technical Field
The invention belongs to the field of machinery, and particularly relates to a welding device and a repairing process for an inner hole abrasion surface of an upper cross beam of a large hydraulic press.
Background
The main working flow of the large-scale hydraulic press for rolling wheels and ring pieces of the rail transit company of the horse steel is that power generated by high-pressure water of 32MPa passing through various regulating valves is used for efficiently driving connected equipment to operate in a rhythmic mode, so that the integrated equipment is arranged on a main cylinder on an inner hole of an upper beam of a main large-scale spare part, a movable plunger in the main cylinder is matched with high precision to perform programmed up-and-down motion, a heated steel ingot is subjected to upsetting and perforation through various forming dies, and the first working procedure of critical standardization for producing finished wheels and ring pieces is precisely achieved. The standard components of various wheels and ring parts are produced, and the product of the first procedure is only required to be rolled by a ring rolling machine, thermally printed, thermally treated, finished product processed and the like. The important production process method has wide application in the industrial field of wheel and ring production for a long time. The upper beam of the core spare part of the 30MN large-sized hydraulic press is made of ZG35; the weight was 35T. Because the long-term high-strength full-load is matched with the master cylinder and the movable plunger in the master cylinder to carry out programmed up-and-down movement, the abrasion of the upper and lower contact surfaces of the inner hole of the upper cross beam and the outer side of the master cylinder is caused, and the size of the abrasion surface of the inner hole of the upper cross beam is increased, a certain gap is generated with the outer side of the matched master cylinder, the unstable factor of the whole coordinated rolling production of the large hydraulic press is seriously caused, thereby influencing the rolling product, if the upper cross beam of a new 30MN large hydraulic press core spare part is replaced, not only the cost of millions of spare parts is required, but also the period of purchasing and processing the new spare part is long because no spare part is needed, and the production is influenced. In order to recover production as soon as possible, it is necessary to design a simple repair device and use the welding repair device to formulate and perfect the wear surface overlaying and heat treatment processes based on different base materials, so as to ensure that the worn upper beam can be reused economically, safely and reliably.
At present, various ZG35 spare part build-up welding repair applications are common, but the welding repair of the ZG35 spare part of the upper beam of the large hydraulic machine is not described in the literature, and the main difficulty of the welding repair of the upper beam of the large hydraulic machine is that after the welding processes of heating, operating, heat preservation and the like of the inner hole wearing surface part of the upper beam to be welded are completed, the upper beam of the whole large hydraulic machine must be ensured not to be structurally deformed, and other assemblies which do not affect rolling are matched with the precision installation of the upper beam of the large hydraulic machine to generate various substandard performances of internal tissues. In addition, the upper cross beam of the large hydraulic press after surfacing meets the requirement that the machining reaches the operation size, and the surface cannot have any welding defects so as to avoid the subsequent influence on the quality of the operation period.
Disclosure of Invention
Aiming at the problems that rolling products are affected after spare parts of the upper beam of the large-sized hydraulic press are worn out, if the spare parts are replaced, the scheduled manufacturing time is relatively long, the investment cost is high, production stopping is caused, and the loss is relatively large, the welding device and the repairing process for the inner hole wearing surface of the upper beam of the large-sized hydraulic press are designed and manufactured by utilizing the existing resources, the investment cost is low, the on-site operation and maintenance are convenient, the repairing time is short, the production stopping time and the production stopping loss are greatly reduced, the upper beam after welding and repairing completely meets the service cycle of the large-sized hydraulic press, and the purchase cost of the upper beam of the large-sized hydraulic press is greatly reduced.
The technical scheme for solving the technical problems is as follows:
the invention relates to a welding device for an inner hole wearing surface of an upper beam of a large hydraulic press, which is characterized by comprising a bottom plate, a supporting seat, a sleeper, a welding gun and a central annular heating device; the center annular heating device is arranged in the center of the upper surface of the bottom plate, the supporting seats are arranged on the left side and the right side of the upper surface of the bottom plate in parallel, and sleepers are respectively arranged on each supporting seat; the welding gun is arranged at the central annular heating device.
As a further improvement of the technical scheme of the invention, the central annular heating device comprises a cylindrical heater support arranged at the center of the bottom plate, a gas pipeline and a plurality of nozzles; an upper annular heating pipe and a lower annular heating pipe are respectively arranged at the upper part and the lower part of the outer side of the heater support, and are communicated with the gas transmission pipeline; the nozzles are uniformly arranged on the outer sides of the upper annular heating pipe and the lower annular heating pipe respectively.
As a further improvement of the technical scheme of the invention, the gas pipeline is characterized in that a pressure gauge is also arranged on the gas pipeline.
As a further improvement of the technical scheme of the invention, the bottom plate is a rectangular steel plate with the thickness of 50mm, and the supporting seat is H-shaped steel with the specification of 250 mm.
As a further improvement of the technical scheme of the invention, the upper annular heating pipe and the lower annular heating pipe are fixedly connected to the heater support through a plurality of connecting rods respectively.
The other technical scheme for solving the technical problems is as follows:
the invention relates to a repairing technology of an inner hole abrasion surface of an upper cross beam of a large hydraulic press, wherein upright post holes are symmetrically arranged on the left side and the right side of the upper cross beam respectively, an inner hole is arranged at the center of the upper cross beam, a plurality of inner hole upper abrasion surfaces and lower abrasion surfaces are respectively formed at the upper position and the lower position of the inner hole of the upper cross beam after the upper cross beam runs for a long time, the repairing technology is carried out by applying the welding device of the inner hole abrasion surface of the upper cross beam of the large hydraulic press, and comprises the following steps:
step one, processing and setting the welding device; according to the specification of the upper beam to be repaired, processing and manufacturing the welding device for the inner hole abrasion surface of the upper beam of the large-sized hydraulic press in the technical scheme, and placing the upper beam on the welding device;
step two, preparing before welding;
2.1 The welding equipment adopts a digital control inversion type manual direct current welding machine, the welding rod adopts an E5015 welding rod, and the temperature is kept after baking, and the welding rod is taken along with use;
2.2 The defect back chipping equipment is a carbon arc gouging machine matched with a plasma gouging machine;
2.3 Oil stains, oxide layers, moisture and the like cannot be generated on the welding position area and the welding rod, and metallic luster needs to be exposed;
2.4 And welding technical requirements: the overlay welding layer is fused with the base metal, and the welding joint cannot have any welding defect;
2.5 The upper cross beam is made of ZG35;
2.6 Auxiliary facilities: the device comprises a heat preservation barrel, a sample plate, a thermometer, a magnifying glass, a mask, a glove, a slag removing hammer, a chisel, a file, a wire brush, sand paper, a steel ruler, a level bar, an adjustable wrench, a straight grinder, an angle grinder, a wire pliers, a steel saw blade, labor protection articles and the like;
2.7 Determining welding process parameters according to the specification of the upper cross beam;
preheating the upper and lower abrasion surfaces of the inner hole of the upper cross beam;
the upper and lower abrasion surfaces of the inner hole of the upper beam are symmetrically and sectionally welded and overlaid in an up-down symmetrical manner, the upper and lower abrasion surfaces of each inner hole on the upper beam are symmetrically marked in sections by a steel ruler and a level bar before welding, then the upper and lower abrasion surfaces of the inner hole are preheated by a central annular heating device on the mounted welding device, the heating temperature of each nozzle is uniformly transferred from outside to inside, and the preheating temperature is set to 80-150 ℃;
welding and post-welding heat treatment of upper and lower abrasion surfaces of an inner hole of an upper beam;
4.1 After the upper and lower wear surfaces of the inner hole reach the preheating temperature set by the process, vertical welding and upward surfacing are performed by adopting an E5015 welding rod with equal strength, first, bottom layer welding is performed, linear strip conveying and rapid short arc welding are performed, the welding seam is required to meet the combination of the bottom part of the welding and a molten pool and the fusion between the upper and lower welding seams, the welding seam is cleaned by adopting a slag removing hammer and an angle grinder after the bottom layer welding, and then, whether the welding seam has welding defects or not is checked by utilizing a magnifying glass which is 10 times, and once the welding defects such as cracks, air holes and the like are found, a plasma gouging cutting machine is immediately adopted for back gouging welding repair;
4.2 After no defect is confirmed in the bottoming layer, a welding gun is started again to weld two layers and more than two filling layers and a cover layer by adopting an E5015 welding rod with equal strength, a short arc of a regular triangle strip conveying method or a medium arc length of 5-8 mm is adopted to build up welding, the welding seam of the cover layer is required to cover the welding seam width of the overlaying layer and the upper beam body so as to ensure the required size of subsequent mechanical processing, then the omnibearing welding inspection is carried out, and the welding gun can be removed after the qualification of the welding gun is directly observed or searched by a magnifying glass with the magnification of 10 times and no welding defect is confirmed;
4.3 Restarting the central annular heating device to continuously heat the upper and lower abrasion surfaces of the inner hole of the upper beam of the large hydraulic press to 450-550 ℃, and preserving heat for 10 hours and slowly cooling until cooling to room temperature;
4.4 And finally, machining the upper and lower abrasion surfaces of the inner hole of the upper beam of the large hydraulic press after welding repair is finished on site by adopting a machine tool until the upper and lower abrasion surfaces meet the assembly size, and delivering the upper and lower abrasion surfaces to use after acceptance and meeting the installation requirement.
As a further improvement of the technical scheme of the invention, when the welding device for the inner hole wearing surface of the upper cross beam of the large hydraulic press is manufactured according to the specification of the upper cross beam to be repaired, firstly, a rectangular steel plate with the area larger than the bottom surface of the upper cross beam and 50mm thick is cut and used as a bottom plate, one surface is horizontally placed on the ground, the other surface is horizontally and symmetrically welded and connected with two H-shaped steel with the specification of 250mm and used as a supporting seat according to the positions of the left and right upright post holes of the upper cross beam, sleepers are fixedly placed on the grooves of the supporting seat, then the upper cross beam is placed on the sleepers, firstly, the upper cross beam of the large hydraulic press is stably and horizontally placed under the condition that the height is met, secondly, a central annular heating device is installed at the inner hole of the upper cross beam, and finally, a welding gun is arranged and an included angle of 70-85 DEG is ensured between welding rods and surfacing welding surfaces at the upper and lower wearing surface of the inner hole.
As a further improvement of the technical scheme of the invention, the E5015 welding rod adopted in the repairing process is baked for 2 hours at 300-350 ℃ and then is kept at a constant temperature, and the welding rod is taken along with use.
As a further improvement of the technical scheme of the invention, the central annular heating device is utilized to preheat the upper and lower abrasion surfaces of the inner hole to 80-150 ℃ before welding, so that the preheating temperature is ensured to be uniformly increased at 20 ℃/h; after welding repair, the central annular heating device is used for heating the upper and lower abrasion surfaces of the inner hole to 450-550 ℃, so that the heating temperature is ensured to be uniformly increased at 100 ℃/h.
As a further improvement of the technical scheme of the invention, the bottom layer adopts an E5015 welding rod with phi 4.0mm, the welding current is 120-160A, the arc voltage is 22+/-1V, the welding speed is 15+/-1 cm/min, the filling layer and the covering layer adopt E5015 welding rods with phi 5.0mm, the welding current is 140-180A, the arc voltage is 25+/-1V, and the welding speed is 17+/-1 cm/min.
Compared with the prior art, the welding device for the inner hole wearing surface of the upper beam of the large-sized hydraulic press has the advantages of simple, novel and practical structure, safe and easy operation, stable welding quality, lower investment cost, high working efficiency, capability of meeting the actual field requirement, greatly reducing the maintenance cost, reducing the shutdown loss caused by the wearing and replacing of the upper beam, and guaranteeing the assembly of wheels and ring members with various specifications.
Drawings
The invention is further described with reference to the drawings and detailed description which follow:
FIG. 1 is a schematic structural view of a welding device for an inner hole wear surface of an upper cross beam of a large hydraulic press;
FIG. 2 is a schematic top view of a welding device for the inner bore wear surface of the upper cross beam of the large hydraulic press;
FIG. 3 is a schematic view of the structure of the upper beam of the hydraulic press according to the present invention;
FIG. 4 is a schematic top view of the upper cross beam of the hydraulic press according to the present invention;
in the figure: 1. base plate 2, support base 3, crosstie 4, upper cross member 5, heater support 6, upper bore wear surface 7, lower bore wear surface 8, upper annular heating tube 9, nozzle 10, pressure gauge 11, gas line 12, welding gun 13, connecting rod 14, column bore 15, central annular heating device 16, lower annular heating tube 17, inner bore.
Detailed Description
Example 1:
as shown in fig. 1 to 4, the welding device for the inner hole wearing surface of the upper beam of the large-scale hydraulic press is characterized by comprising a bottom plate 1, a supporting seat 2, a sleeper 3, a welding gun 12 and a central annular heating device 15; the bottom plate 1 is a rectangular steel plate with the thickness of 50mm, the center of the upper surface of the bottom plate is provided with the central annular heating device 15, the left and right sides of the upper surface of the bottom plate are provided with the supporting seats 2 in parallel, each supporting seat 2 is provided with a sleeper 3, and the supporting seats 2 can be manufactured by H-shaped steel with the specification of 250 mm; the welding gun 12 is arranged at a central annular heating device 15.
In this embodiment, the central annular heating device 15 comprises a cylindrical heater support 5 arranged at the center of the soleplate 1, a gas transmission pipeline 11 and a plurality of nozzles 9; an upper annular heating pipe 8 and a lower annular heating pipe 16 are respectively arranged at the upper and lower parts of the outer side of the heater support 5, and the upper annular heating pipe 8 and the lower annular heating pipe 16 are communicated with the gas pipeline 11; the nozzles 9 are uniformly arranged on the outer sides of the upper annular heating pipe 8 and the lower annular heating pipe 16 respectively so as to uniformly heat the inner hole abrasion surface of the upper beam.
In this embodiment, the gas pipe 11 is further provided with a pressure gauge 10, a control valve, and other components.
In this embodiment, in order to facilitate the arrangement of the upper annular heating tube 8 and the lower annular heating tube 16 on the heater support, the upper annular heating tube 8 and the lower annular heating tube 16 are respectively fixedly connected to the heater support 5 through a plurality of connecting rods.
Example 2:
as shown in fig. 1 to 4, in the repairing process of the inner hole wear surface of the upper beam of the large hydraulic press, upright holes 14 are symmetrically arranged on the left and right sides of the upper beam 4, an inner hole 17 is arranged at the center of the upper beam, the upper beam 4 forms a plurality of inner hole upper wear surfaces 6 and inner hole lower wear surfaces 7 at the upper and lower positions of the inner hole 17 respectively after long-term operation, and the repairing process is carried out by applying the welding device of the inner hole wear surfaces of the upper beam of the large hydraulic press, and comprises the following steps:
step one, processing and manufacturing a welding device of an inner hole abrasion surface of an upper beam of the large-sized hydraulic press; processing and manufacturing a welding device for an inner hole wearing surface of an upper beam of the large hydraulic press according to the specification of the upper beam 4 to be repaired, and placing the upper beam 4 on the welding device after the welding device is manufactured; when the welding device is manufactured, firstly, a rectangular steel plate with the area larger than the bottom surface of the upper beam 4 and the thickness of 50mm is cut as the bottom plate 1, one surface is horizontally placed on the ground, the other surface is horizontally and symmetrically welded and connected with two H-shaped steels with the specification of 250mm on the bottom plate 1 as the supporting seats 2 according to the positions of the left and right column holes 14 of the upper beam 4, the sleepers 3 are fixedly placed on the grooves of the supporting seats 2, then the upper beam 4 is rotated on the two sleepers 3, firstly, the upper beam 4 of the whole large-sized hydraulic press is ensured to be stably and horizontally placed under the condition of meeting the height, secondly, the contact surfaces of the bottom surfaces of the four column holes 14 of the upper beam 4 are not damaged by the sleepers 3, and then all components of the central annular heating device 15 are installed, the heater support 5 is placed in the middle of an inner hole 17 of the upper cross beam 4, an upper annular heating pipe 8 and a lower annular heating pipe 16 are placed according to the middle of an upper abrasion surface 6 and a lower abrasion surface 7 of the inner hole and fixedly welded on the heater support 5 by adopting a plurality of connecting rods 13, then a plurality of nozzles 9 are uniformly arranged on the upper annular heating pipe 8 and the lower annular heating pipe 16, a pressure gauge 10 is arranged on a conveying air pipe 11, and an air source is communicated to ensure that the welding device is provided with preheating, heating and heat preservation processes of the upper abrasion surface 6 and the lower abrasion surface 7 of the inner hole before welding repair, and finally a welding gun 12 is arranged and ensures that an included angle between welding rods and surfacing surfaces of the welding rods of the welding gun 12 at the welding positions of the upper abrasion surface 6 and the lower abrasion surface 7 of the inner hole can be 70-85 degrees;
step two, preparing before welding;
2.1, adopting an HT400D digital control inversion type manual direct current welder for welding equipment, adopting a 600A welding handle as a welding gun 12, adopting an E5015 welding rod with the diameter phi of 4.0mm and the diameter phi of 5.0mm as a welding rod, baking for 2 hours at 300-350 ℃ and then keeping constant temperature, and taking along with use;
2.2, the defect back chipping equipment is a carbon arc gouging ZX5-630 welding machine matched with a plasma gouging LGK-100MA;
2.3, oil stains, oxide layers, moisture and the like cannot be generated on the welding position area and the welding rod, and metallic luster needs to be exposed;
2.4, welding technical requirements: the overlay welding layer is fused with the base metal, and the welding joint cannot have any welding defect;
2.5, the upper cross beam 4 is made of ZG35;
2.6 auxiliary facilities: the device comprises a heat preservation barrel, a sample plate, a thermometer, a magnifying glass, a mask, a glove, a slag removing hammer, a chisel, a file, a wire brush, sand paper, a steel ruler, a level bar, an adjustable wrench, a straight grinder, an angle grinder, a wire pliers, a steel saw blade, labor protection articles and the like;
2.7, determining welding process parameters according to the specification of the upper beam 4;
manual welding rod arc welding
Step three, preheating upper and lower abrasion surfaces 6 and 7 of an inner hole of the upper cross beam 4;
because the upper and lower wear surfaces 6, 7 of the inner hole of the upper beam 4 of the large-scale hydraulic press are larger, consider if the large-area build-up welding must produce the structural member deformation of the whole upper beam, lead to scrapping of the upper beam of the large-scale hydraulic press directly, so in order to ensure repair welding and meet the technological requirement for long term, and can not scrapping the whole upper beam, adopt the way of up-down symmetrical sectional vertical welding build-up welding on the upper and lower wear surfaces 6, 7 of the inner hole of the upper beam 4 of the large-scale hydraulic press, both meet the subsequent machining dimension of the inner hole wear surface of the upper beam and prevent the deformation of the whole structural member, before welding, the upper and lower wear surfaces 6, 7 of each inner hole on the upper beam 4 are respectively marked by adopting a steel ruler and a horizontal ruler in a sectional symmetry way, then the central annular heating device 15 on the welding device is utilized to carry out the integral preheating of the upper and lower wear surfaces 6, 7 of the inner hole, the temperature heated by each nozzle 9 is uniformly transferred from outside to the inside, the preheating temperature is set to 80-150 ℃, the preheating temperature is ensured to be uniformly increased by 20 ℃/h, so as to avoid uneven high-temperature heating, and the inner hole of the large-scale hydraulic press is greatly reduced, the inner hole is greatly reduced in the internal heat stress of the upper and the inner hole is greatly reduced, the internal heat is hardened, and the internal is greatly reduced, the internal is caused by the heat stress is reduced;
welding and post-welding heat treatment of the upper and lower abrasion surfaces 6 and 7 of the inner holes of the upper beam 4; 4.1, after the upper and lower wear surfaces 6 and 7 of the inner hole reach the preheating temperature set by the process, adopting an E5015 electrode with equal strength to weld up and build up welding, firstly adopting a bottom layer welding, adopting an electrode with the diameter of 4.0mm to weld up and build up welding, adopting a vertical welding mode to build up welding, ensuring that the current is slightly smaller, adopting a linear strip conveying mode to weld quickly and short-arc, ensuring that the welding seam is not too wide but the combination of the bottom part of the welding seam and a molten pool and the fusion between the upper and lower welding seams are required, adopting a slag removing hammer and an angle grinder to clean the welding seam after the bottom layer welding, checking whether the welding seam has welding defects by using a magnifying glass which is 10 times, and adopting a plasma gouging cutting machine to weld back immediately once the welding defects such as cracks and air holes are found, wherein the interlayer temperature is required to be ensured for both secondary welding repair and subsequent filling layer and cover layer welding;
4.2, after confirming the defect-free bottom layer, starting the welding gun to weld two layers and more than two filling layers and a cover layer by adopting an E5015 welding rod with equal strength, overlaying welding by adopting a welding rod with the diameter of 5.0mm, carrying out short arc by adopting a regular triangle strip conveying method or carrying out medium arc length of 5-8 mm, and dismantling the welding gun 12 after the welding seam of the cover layer is required to cover the welding seam width (10-25 mm) of the overlaying layer and the upper beam body so as to ensure that the following machining needs to have enough thickness, carrying out omnibearing welding inspection, directly observing or searching for qualification by using a magnifying glass with the size of 10 times and confirming that no welding defect exists;
4.3, restarting the central annular heating device to continuously heat the upper and lower wearing surfaces 6 and 7 of the inner hole of the upper beam 4 of the large hydraulic press to 450-550 ℃, ensuring that the heating temperature is uniformly increased at 100 ℃/h when heating, keeping the temperature for 10 hours and slowly cooling until cooling to room temperature after the heating temperature is reached, keeping the temperature for 10 hours to reduce the hardening degree, avoiding embrittlement, eliminating the welding stress and reaching the process temperature required by welding;
and 4.4, finally, machining the upper and lower abrasion surfaces 6 and 7 of the inner hole of the upper beam 4 of the large hydraulic press after welding repair by adopting a machine tool on site until the assembly size is met, and completely meeting the requirements of the inner hole of the upper beam of the large hydraulic press, other rolling assemblies and the upper beam installation by on-site practical template inspection and acceptance, delivering the assembly to use, and achieving the mechanical performance using effect by periodic wheel and ring rolling operation inspection.
The above is only a preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions easily contemplated by those skilled in the art within the technical scope of the present invention should be covered by the present invention. Therefore, the protection scope of the present invention should be defined by the claims.
Claims (6)
1. A repair process for inner hole wear surfaces of an upper cross beam of a large hydraulic press is characterized in that upright column holes (14) are symmetrically formed in the left side and the right side of the upper cross beam (4), inner holes (17) are formed in the center of the upper cross beam, the upper cross beam (4) is respectively provided with a plurality of inner hole upper and lower wear surfaces (6, 7) at the upper and lower positions of the inner holes (17) after long-term operation, and the repair process is characterized in that a welding device for the inner hole wear surfaces of the upper cross beam of the large hydraulic press is used for repairing, and the welding device comprises a bottom plate (1), a supporting seat (2), a sleeper (3), a welding gun (12) and a central annular heating device (15); the center annular heating device (15) is arranged in the center of the upper surface of the bottom plate (1), the supporting seats (2) are arranged on the left side and the right side of the upper surface of the bottom plate (1) in parallel, and sleepers (3) are respectively arranged on each supporting seat (2); the welding gun (12) is arranged at the central annular heating device (15); the central annular heating device (15) comprises a cylindrical heater support (5), a gas pipeline (11) and a plurality of nozzles (9), wherein the cylindrical heater support is arranged at the center of the bottom plate (1); an upper annular heating pipe (8) and a lower annular heating pipe (16) are respectively arranged on the outer side of the heater support (5) up and down, and the upper annular heating pipe (8) and the lower annular heating pipe (16) are communicated with the gas pipeline (11); the nozzles (9) are uniformly arranged on the outer sides of the upper annular heating pipe (8) and the lower annular heating pipe (16) respectively; the repair process comprises the following steps:
step one, processing and setting the welding device; the welding device of the inner hole abrasion surface of the upper cross beam of the large hydraulic press is manufactured according to the specification of the upper cross beam (4) to be repaired, and the upper cross beam (4) is placed on the welding device; during manufacturing, firstly, a rectangular steel plate with the area larger than the bottom surface of the upper beam (4) is cut to be used as a bottom plate (1), one surface of the rectangular steel plate is horizontally placed on the ground, the other surface of the rectangular steel plate is horizontally and symmetrically welded on the bottom plate (1) according to the positions of the left and right column holes (14) of the upper beam (4), two H-shaped steels with the specification of 250mm are used as supporting seats (2), a sleeper (3) is fixedly placed on a groove of the supporting seats (2), then the upper beam (4) is placed on the sleeper (3), firstly, the upper beam (4) of the integral large hydraulic press is stably and horizontally placed under the condition that the height is met, secondly, the contact surfaces of the bottom surfaces of the four column holes (14) of the upper beam (4) are not damaged through the sleeper (3), then a central annular heating device (15) is installed at an inner hole (17) of the upper beam (4), and finally, a welding gun (12) is arranged, and the welding rod following surface of the welding gun (12) can form an included angle of 70-85 DEG at the welding rod welding positions of the upper and lower abrasion surfaces (6 and 7) of the inner hole;
step two, preparing before welding;
2.1 The welding equipment adopts a digital control inversion type manual direct current welding machine, the welding rod adopts an E5015 welding rod, and the temperature is kept after baking, and the welding rod is taken along with use;
2.2 The defect back chipping equipment is a carbon arc gouging machine matched with a plasma gouging machine;
2.3 Oil stains, oxide layers and moisture are not required to be formed on the welding position area and the welding rod, and metallic luster is required to be exposed;
2.4 And welding technical requirements: the overlay welding layer is fused with the base metal, and the welding joint cannot have any welding defect;
2.5 The upper cross beam (4) is made of ZG35;
2.6 Auxiliary facilities: the device comprises a heat preservation barrel, a sample plate, a temperature measuring instrument, a magnifying glass, a mask, a glove, a slag removing hammer, a chisel, a file, a steel wire brush, sand paper, a steel ruler, a level bar, an adjustable wrench, a straight grinder, an angle grinder, a wire pliers, a steel saw blade and labor protection articles;
2.7 Determining welding process parameters according to the specification of the upper cross beam (4);
preheating upper and lower abrasion surfaces (6, 7) of an inner hole of the upper cross beam (4);
the upper and lower abrasion surfaces (6, 7) of the inner hole of the upper beam (4) are symmetrically and sectionally welded and overlaid in an up-down symmetrical mode, before welding, the upper and lower abrasion surfaces (6, 7) of each inner hole on the upper beam (4) are symmetrically marked in sections by adopting a steel ruler and a level ruler respectively, then the upper and lower abrasion surfaces (6, 7) of the inner hole are preheated by utilizing a central annular heating device (15) on the welding device, the heating temperature of each nozzle (9) is uniformly transferred from outside to inside, and the preheating temperature is set to 80-150 ℃;
welding and postweld heat treatment of upper and lower abrasion surfaces (6, 7) of an inner hole of the upper cross beam (4);
4.1 After the upper and lower wear surfaces (6, 7) of the inner hole reach the preheating temperature set by the process, the vertical welding of the E5015 welding rod with equal strength is adopted to build up welding, the bottom layer is firstly welded, the straight line transportation strip is quickly welded in a short arc mode, the welding seam is required to meet the combination of the bottom part of the welding and a molten pool and the fusion between the upper and lower welding seams, the welding seam is cleaned by adopting a slag removing hammer and an angle grinder after the bottom layer is welded, and then the welding seam is inspected by using a magnifying glass with 10 times of welding defects, and once the welding defects of cracks and air holes are found, a plasma gouging cutting machine is immediately adopted for back gouging welding repair;
4.2 After no defect is confirmed in the bottoming layer, a welding gun is started again to weld two layers and more than two filling layers and a cover layer by adopting an E5015 welding rod with equal strength, a short arc of a regular triangle strip conveying method or a medium arc length of 5-8 mm is adopted to build up welding, the welding seam of the cover layer is required to cover the welding seam width of the surfacing layer and the upper beam body so as to ensure the required size of subsequent mechanical processing, then the omnibearing welding inspection is carried out, and the welding gun (12) can be removed after the qualification of the welding gun is directly observed or searched by a magnifying glass with the magnification of 10 times and no welding defect is confirmed;
4.3 Continuously heating the upper and lower abrasion surfaces (6, 7) of the inner hole of the upper cross beam (4) of the large hydraulic press to 450-550 ℃ by restarting the central annular heating device, and slowly cooling the upper and lower abrasion surfaces for 10 hours until the upper and lower abrasion surfaces are cooled to room temperature;
4.4 And finally, machining the upper and lower abrasion surfaces (6, 7) of the inner hole of the upper beam (4) of the large hydraulic press after welding repair by adopting a machine tool on site until the assembly size is met, and delivering the upper and lower abrasion surfaces after acceptance and meeting the installation requirement.
2. The repairing process of the inner hole abrasion surface of the upper cross beam of the large hydraulic press according to claim 1, wherein the E5015 welding rod adopted in the repairing process is baked for 2 hours at 300-350 ℃ and then is kept at a constant temperature, and the repairing process is used at any time.
3. The repair process of the inner hole abrasion surface of the upper cross beam of the large hydraulic press according to claim 1, wherein the preheating temperature is ensured to be uniformly increased at 20 ℃/h when the upper and lower abrasion surfaces (6, 7) of the inner hole are preheated to 80-150 ℃ by using a central annular heating device (15) before welding; after welding repair, the central annular heating device (15) is used for heating the upper and lower abrasion surfaces (6, 7) of the inner hole to 450-550 ℃, so that the heating temperature is ensured to be uniformly increased at 100 ℃/h.
4. The repair process of the inner hole abrasion surface of the upper beam of the large hydraulic press according to claim 1, wherein the bottom layer is made of E5015 welding rods with phi of 4.0mm, the welding current is 120-160A, the arc voltage is 22+/-1V, the welding speed is 15+/-1 cm/min, the filling layer and the covering layer are made of E5015 welding rods with phi of 5.0mm, the welding current is 140-180A, the arc voltage is 25+/-1V, and the welding speed is 17+/-1 cm/min.
5. The repairing process of the inner hole abrasion surface of the upper cross beam of the large hydraulic press according to claim 1, wherein the gas transmission pipeline (11) is further provided with a pressure gauge (10).
6. The repairing process of the inner hole abrasion surface of the upper cross beam of the large hydraulic press according to claim 1, wherein the upper annular heating pipe (8) and the lower annular heating pipe (16) are respectively fixedly connected to the heater support (5) through a plurality of connecting rods (13).
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| CN114309880B (en) * | 2022-01-28 | 2023-05-09 | 安徽马钢设备检修有限公司 | Welding repair process for surface abrasion part of vertical column hole of lower beam of large hydraulic press |
| CN114888399A (en) * | 2022-04-20 | 2022-08-12 | 安徽马钢设备检修有限公司 | 32MPa pump head liquid inlet and outlet valve box valve hole abrasion welding device and welding process |
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