Steel member machining process

Abstract

The invention discloses a steel member machining process which comprises the following steps: firstly, flattening a hot-rolled steel plate by adopting a double-roller flattening machine; secondly, accurately cutting the leveled steel plate by using a numerical control flame cutting machine; then, a numerical control milling machine is adopted for milling the end of the steel component, it is ensured that the end face is flat, and the perpendicularity meets the standard requirement; secondly, the steel member is subjected to groove machining through an automatic groove machine, and the groove angle and depth are accurately controlled; and finally, the steel member is assembled through a hydraulic pressing device, a hydraulic straightening machine is used for arching treatment, and it is ensured that the geometrical shape of the steel member meets the design requirement. According to the technology, through application of full-automatic equipment, the machining process is optimized, errors caused by manual operation are reduced, the production efficiency and the machining precision are improved, and the reliability and safety of the steel member in actual engineering are ensured.

Description

Technical Field

[0001] The invention belongs to the field of steel structure processing, and in particular relates to a steel component processing technology. Background Art

[0002] Steel structure components need to undergo multiple processing steps during the manufacturing process, including steel plate leveling, cutting, splicing, welding, etc. In the prior art, the process steps of steel component processing have problems such as low efficiency, difficult quality assurance, and unstable processing accuracy. There is an urgent need for a steel component processing technology that can improve processing quality, reduce processing difficulty, and improve efficiency. Summary of the invention

[0003] In order to solve the above problems, the present invention discloses a steel component processing technology, which ensures the stable processing quality of the steel component and meets the design and safety requirements by optimizing the precision control and process parameter setting of each processing step.

[0004] To achieve the above object, the technical solution of the present invention is as follows: A steel component processing process comprises the following steps: S1.Steel plate leveling: Use double roller leveling machine or multi-roller leveling machine for leveling; The steel plate is sent to the leveling machine for preliminary leveling. When the width of the steel plate is between 500mm and 3000mm and the thickness is between 6mm and 80mm, a double-roller leveling machine is used. When the thickness exceeds 80mm, a multi-roller leveling machine is used; After the initial leveling, measure and check the bending degree of the steel plate, and use a laser measuring instrument or a two-dimensional level to measure the flatness of the steel plate; If the bending degree of the steel plate exceeds the specified range (±1.0mm), a hydraulic straightening machine is used for secondary correction; The flatness of the steel plate requires that the flatness error does not exceed ±1.0mm, especially the verticality of the H-shaped steel web is required to be controlled within b / 100 (b is the width of the steel member) and not greater than 1.0mm.

[0005] S2. Material splicing: Use automatic welding machines, mechanical connection devices (such as bolt connectors), and hydraulic clamps for splicing; According to the design drawings, the materials required for the steel components are pre-assembled, and the steel joints are preliminarily welded using an automatic welding machine. Before welding, the joint surface should be cleaned to remove impurities such as oil, rust, etc. Use hydraulic clamps to fix during the splicing process to ensure that the splicing position does not move; All-position welding is adopted at the joints, and the width and depth of the weld must meet the design requirements; The joint strength of the splicing parts must be subjected to non-destructive testing, such as ultrasonic testing or X-ray testing, to ensure that there are no cracks or pores.

[0006] S3. Cutting: Cutting by CNC flame cutting machine, laser cutting machine, plasma cutting machine; According to the size requirements of the components, use CNC flame cutting machine or laser cutting machine to cut the steel plate; When using a CNC cutting machine, the cutting accuracy should be controlled within ±1.0mm. During the cutting process, the temperature and pressure of the cutting head should be kept stable to prevent uneven cutting surfaces. Clean the cut steel plate to remove the slag and ensure the cut surface is smooth. If there are obvious burrs or unevenness on the cut surface, it should be mechanically ground.

[0007] S4. End milling: Use CNC milling machine to mill the end of steel components. The milling accuracy requirement is ±0.5mm to ensure the end surface is flat; According to the design requirements, the flatness of the milling rear end should be controlled at ≤0.3mm, and the end verticality should not exceed 2.0mm; Measure the end face of the milled steel component to ensure that it is perpendicular to the axis, and use a level and laser positioning device for precise calibration.

[0008] S5. Beveling: Use an automatic beveling machine to bevel the ends of steel components. The bevel angle is usually 45°, but it can be adjusted according to actual design requirements. The surface after groove processing needs to be flattened to ensure that there are no burrs and the cutting depth does not exceed 0.3mm. Use ultrasonic testing or visual inspection to ensure that there are no cracks or pores on the groove surface. After groove processing, the steel components need to be cleaned of stains, grease and other impurities in the welding area to ensure the welding quality of the groove area.

[0009] S6. Assembly: According to the design drawings of the steel components, use precision fixtures to accurately position and fix the steel components.

[0010] During assembly, the connecting parts of the steel components are welded and auxiliary fixation is performed using welding positioning frames to ensure the accuracy of each connection point; During the assembly process, a hydraulic clamping device is used to ensure the tight connection of the joints to avoid loose structure due to loose joints; After welding is completed, the welding points are subjected to non-destructive testing to ensure the welding quality, especially the welding depth and weld flatness.

[0011] S7. Arching and correction: According to the design requirements, the steel beams are arched to ensure that the steel components will not be deformed due to uneven force during long-term use; After the arching treatment, the steel components are corrected using a hydraulic straightening machine to ensure that the curvature of the steel components is controlled within ±2.0mm; After welding, if the steel component is partially deformed, use flame straightening equipment to perform thermal straightening to ensure that the deformed component meets the design requirements; The corrected steel components need to be checked again to ensure that their geometric dimensions and shapes meet the design requirements.

[0012] The beneficial effects of the present invention are: (1) The present invention can significantly improve the geometric dimensional accuracy and welding quality of steel components by precisely controlling the accuracy of the steps of steel plate leveling, cutting, end milling and groove processing, and ensure that the processed steel components meet the design requirements. By optimizing the process steps and equipment configuration, the process of the present invention can complete the processing of steel components in a shorter period of time, effectively shorten the production cycle, and improve production efficiency.

[0013] (2) This process reduces the waste of raw materials and energy consumption by optimizing the use of equipment and reducing repeated processing steps, thereby achieving cost savings. Each processing step, such as steel plate leveling, cutting, beveling, etc., uses high-precision equipment, combined with technical means such as non-destructive testing, effectively avoiding quality fluctuations in production and improving the quality stability of the final product. In the processing of steel components, this application focuses on the control of welding strength and precision to ensure the firmness of each connection point and reduce safety hazards caused by unstable or unqualified structures. DETAILED DESCRIPTION

[0014] The present invention will be further explained below in conjunction with specific embodiments. It should be understood that the following specific embodiments are only used to illustrate the present invention and are not used to limit the scope of the present invention. It should be noted that the words "front", "rear", "left", "right", "up" and "down" used in the following description refer to directions, and the words "inside" and "outside" refer to directions toward or away from the geometric center of a specific component, respectively.

[0015] Example 1 S1. Steel plate preparation: Use hot-rolled steel plates with a thickness of 10mm and a width of 1500mm, and there should be no obvious defects on the steel surface. Clean the hot-rolled steel plates and fix them in the feeding area of ​​the leveling machine to ensure that there is no dirt, oil stains or other impurities that affect leveling on the steel plates.

[0016] S2. Steel plate leveling: Set the pressure of the double-roller leveling machine to 5MPa, adjust the roller distance to 50mm, and start the leveling machine. The steel plate passes between the two opposite rollers of the leveling machine to make its surface stressed and complete the leveling process. At this time, the steel plate needs to go through the leveling process twice to ensure the improvement of flatness.

[0017] S3. Flatness inspection: The flatness of the leveled steel plate is checked by a laser measuring instrument to measure the curvature in the middle and around the steel plate to ensure that the error is controlled within ±1.0mm. According to the measurement results, if the flatness of the steel plate is unqualified, secondary leveling is performed.

[0018] S4. Cutting operation: Send the leveled steel plate to the CNC flame cutting machine and set the cutting parameters (such as flame temperature, cutting speed, oxygen flow, etc.) to ensure that the cutting accuracy requirement is ±1.0mm.

[0019] S5. Cutting quality inspection: Use a laser measuring instrument and caliper to measure the flatness of the cutting edge to ensure that the steel plate cutting accuracy meets the design requirements. Perform a visual inspection of the quality of the cutting area to ensure that there are no burrs or surface defects.

[0020] The laser measuring instrument detected that the flatness error of the steel plate after leveling was ±0.8mm, which met the design requirements. The edge of the steel plate after cutting was flat, and the cutting accuracy was ±0.9mm, which met the process requirements. The combination of the double-roller leveling machine and the CNC flame cutting machine can effectively control the flatness and cutting accuracy of the steel plate. Compared with the traditional manual cutting method, the automated equipment improves the processing accuracy and shows obvious advantages in production efficiency.

[0021] Example 2 S1. End milling: Use H-shaped steel with a thickness of 12mm and a length of 2000mm. Place the H-shaped steel on the CNC milling machine, set the cutting speed of the milling cutter to 1500rpm and the feed speed to 5mm / min. Start the CNC milling machine to mill the end of the H-shaped steel. The milling depth is 0.5mm each time, and it is carried out three times to ensure the milling accuracy.

[0022] S2. Milling quality inspection: Use a laser level to check the flatness of the end face after milling, and check the verticality of the end to ensure that the verticality error of the end face does not exceed 1.5mm and the flatness error does not exceed ±0.5mm.

[0023] S3. Beveling: The milled H-beam is fed into the automatic beveling machine, the beveling angle is set to 45°, and the beveling depth is 0.3mm. The beveling machine uses an automatic control system to accurately process, ensuring the smoothness of the bevel edge and the accuracy of the size.

[0024] S4. Bevel quality inspection: Use an angle gauge to check the bevel angle to ensure that the bevel angle error does not exceed 2°. Use a caliper to measure the bevel depth to ensure that the depth is within the range of 0.3mm±0.05mm.

[0025] The flatness error of the steel component end face after end milling is ±0.3mm, and the verticality error of the end is 1.5mm, which meets the design requirements. The groove angle is 45°±2°, and the groove depth is 0.2mm, which meets the standard. Through the precise control of the CNC milling machine and the automatic groove machine, the geometric accuracy of the end can be effectively guaranteed. Compared with manual processing, this automated method avoids errors and instability, guarantees the groove processing accuracy, and ensures the strength and stability of the welded joint.

[0026] Example 3 S1. Assembly operation: Use I-shaped steel with a thickness of 20mm and a length of 3000mm. Butt the connection parts of the I-shaped steel and use a hydraulic clamping device to clamp the connection parts to ensure that the joints are not loose. Set the pressure of the hydraulic clamping device to 10MPa and maintain the clamping state for 10 minutes to ensure a firm connection.

[0027] S2. Welding operation: After the butt joint is completed, use a welding machine to weld to ensure that the welding process meets the standards. After welding is completed, use non-destructive testing equipment to inspect the weld to ensure that there are no defects such as pores and cracks at the welding point.

[0028] S3. Arching treatment: After welding, the steel structure is transferred to the hydraulic straightening machine, and the straightening pressure is set to 15MPa for arching treatment. The target value of the arching degree is ±2.0mm, and the actual arching degree is controlled within the range of ±1.5mm.

[0029] After non-destructive testing, the welding quality is good and no obvious defects are found in the welds. After the arching treatment, the arching degree of the steel component is 1.5mm, which meets the design requirements. The assembly accuracy is ensured by the hydraulic clamping device, avoiding displacement and error during the assembly process. The use of the hydraulic straightening machine ensures that the arching degree of the steel component is controlled within a reasonable range, avoiding structural deformation caused by uneven force during long-term use.

[0030] The precision of each process step (such as steel plate leveling, cutting, milling, beveling, etc.) of the processing technology provided by the present invention meets the design requirements, and the error is controlled within the allowable range, ensuring the high precision of the entire processing process. By using CNC equipment (such as CNC flame cutting machine, CNC milling machine, automatic beveling machine, etc.), the processing efficiency is greatly improved, the error caused by human operation is reduced, and the production cycle is shortened. Each link of the present invention undergoes strict quality control and testing (such as non-destructive testing, laser measurement, angle gauge, etc.), ensuring the welding quality, dimensional accuracy and structural stability of steel components.

[0031] In summary, the steel component processing technology of the present invention has the advantages of high precision, high efficiency and low cost, and can ensure the quality stability of the steel component and ensure its safety in long-term use in actual engineering.

[0032] It should be noted that the technical idea of ​​the present invention cannot limit the protection scope of the present invention. For ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principle of the present invention. These improvements and modifications all fall within the protection scope of the claims of the present invention.

Claims

1. A steel component processing technology, characterized in that: The following steps are involved: S1.Steel plate leveling: Use double-roller or multi-roller leveling machine to level the steel plate; S2. Material splicing: Use automatic welding machines to splice steel materials, fix the splicing parts with hydraulic clamps, and perform non-destructive testing; S3. Cutting: Use CNC cutting machine or laser cutting machine to cut steel plates, with a cutting accuracy of no more than ±1.0mm; S4. End milling: Use CNC milling machine to mill the ends of steel components, with the accuracy controlled within ±0.5mm, flatness ≤0.3mm, and verticality not greater than 2.0mm; S5. Groove processing: Use an automatic groove machine to groove the ends of steel components. The groove angle is controlled within the range of 45°±5° and the groove depth is ≤0.3mm; S6. Assembly: Use precision fixtures and hydraulic clamping devices to assemble steel components, and perform non-destructive testing after welding; S7. Arching and correction: The steel components shall be arched and corrected using hydraulic straightening machines or flame straightening equipment to ensure that the steel components meet the design requirements.

2. The steel component processing process according to claim 1, characterized in that: In step S1, the flatness error of the steel plate does not exceed ±1.0 mm, and the verticality of the H-shaped steel web is not greater than 1.0 mm.

3. The steel component processing process according to claim 1, characterized in that: In step S1, if the bending of the steel plate exceeds the standard, a hydraulic press is used for secondary correction.

4. The steel component processing process according to claim 1, characterized in that: In step S3, the cutting accuracy is controlled within ±1.0 mm, and the cutting slag is cleaned thoroughly.

5. The steel component processing process according to claim 1, characterized in that: In step S4, the milling accuracy requirement is ±0.5 mm, the flatness of the milling plane is ≤0.3 mm, and the verticality of the end is not greater than 2.0 mm.

6. The steel component processing process according to claim 1, characterized in that: In step S5, the groove angle is controlled within the range of ±5°, and the groove cutting depth is ≤0.3 mm.

7. The steel component processing process according to claim 1, characterized in that: In step S6, a hydraulic clamping device is used during welding to ensure that the joint is tight and the weld depth and quality meet the design requirements.

8. The steel component processing process according to claim 1, characterized in that: In step S7, the deformation of the steel component is controlled within ±2.0 mm, and the size is detected after correction.