Process for reducing deformation of stainless steel composite bridge deck panel block assembly welding

Abstract

The application discloses a process for reducing the deformation of a stainless steel composite bridge deck slab during assembly and welding, which comprises the following steps: assembling platform manufacturing, determining the assembling position of a single element, assembling the stainless steel composite bridge deck slab and the single element, welding, edge cutting and groove cutting. The process does not need to reverse deformation or rigidly fix the jig, and does not need to perform heat correction or mechanical correction after welding. The correct assembly and welding process effectively controls the welding deformation of the bridge deck slab, meets the technical requirements, and achieves good effects. In the actual manufacturing process, a large amount of tooling materials, manpower, material resources and processing efficiency for controlling deformation are saved, the energy is saved, the labor is reduced, the efficiency is improved, and the cost is reduced, and the process can be used as a reference for the manufacturing of similar steel structure bridge deck slab units.

Description

Technical Field

[0001] This invention belongs to the field of manufacturing, processing and welding technology of stainless steel composite steel plate bridge deck for steel structure bridges, and specifically relates to a process for reducing the deformation of stainless steel composite steel plate bridge deck panels during assembly welding. Background Technology

[0002] With the development of metal materials science and steel metallurgy technology in my country, engineering technologies such as railways and high-rise steel structures have been promoted. These technologies feature novel designs and unique shapes, especially large-span bridges and high-rise steel structures, which are emerging rapidly. Furthermore, the variety of materials used in these projects is increasing. Stainless steel composite plates have been gradually and extensively used in railway bridges and special-function steel structure projects. Stainless steel composite plates not only effectively solve the problem of corrosion and rust prevention of steel plates but also eliminate pollution caused by paint coatings. The first steel structure aqueduct project in China used 34mm thick stainless steel composite plates (30mm Q345qD + 4mm 316L) as the aqueduct's bottom plate, with the water-facing side made of stainless steel. The panel unit is 3050mm long and 15600mm wide; the middle of the length direction features a single welded "T"-shaped fish-belly crossbeam with a cross-section height of 2000mm, a web plate thickness of 30mm, and a flange plate thickness of 44mm; the width direction has 16 longitudinally welded "T" ribs with a cross-section height of 470mm, a web plate thickness of 16mm, and a flange plate thickness of 20mm. Due to the dense arrangement of parts and the large amount of welding, with all components located on the underside of the panel, significant welding deformation is inevitable. Furthermore, stainless steel composite panels are not suitable for flame straightening, especially austenitic stainless steel, which is highly susceptible to repeated heating of weldments, easily causing intergranular corrosion defects, loss of strength, and in severe cases, failure of the stainless steel's functionality. Therefore, the assembly and welding processes for stainless steel composite bridge deck panels require in-depth optimization to minimize welding deformation. Summary of the Invention

[0003] To solve the above-mentioned technical problems, the present invention provides a process for reducing the welding deformation of stainless steel composite bridge deck panels for bridges. This process effectively avoids flame straightening, reduces and controls the welding stress and deformation of large-size bridge deck panels, and achieves good results in ensuring the flatness of the panels meets technical requirements. In actual manufacturing and processing, this process truly improves efficiency, saves energy, reduces labor and costs.

[0004] The technical solution of the present invention is as follows:

[0005] A process for reducing welding deformation of stainless steel composite bridge deck panels for bridges, characterized by comprising the following steps:

[0006] S1: Assembly platform fabrication;

[0007] S2: Determine the assembly location of the unit component;

[0008] S3: Stainless steel composite bridge deck and unit assembly;

[0009] S4: Welding;

[0010] S5: Trim edges and bevel.

[0011] Furthermore, in step S1, the assembly platform is welded from steel sections in a lattice structure, and the bridge deck pre-camber is adjusted by a toothed plate to 10mm. A center reference line is drawn at both ends of the longitudinal direction of the assembly platform to locate the center line of the stainless steel composite bridge deck.

[0012] Furthermore, a 20mm thick steel plate is laid on the toothed plate to ensure a 10mm camber. The longitudinal flatness of the steel plate is less than 1mm, and the steel plate is spot-welded to the toothed plate.

[0013] Further, in step S2, the center lines at both ends of the stainless steel composite bridge panel and the assembly positions of the unit components are drawn on the panel.

[0014] Furthermore, the unit component includes a T-shaped fish-belly crossbeam and a T-shaped rib.

[0015] Further, step S3 includes:

[0016] Place the stainless steel composite bridge panel with the base layer side facing up on the assembly platform, and align the center reference lines of both longitudinal ends of the stainless steel composite bridge panel with the center reference lines of both ends of the assembly platform.

[0017] According to the center lines at both ends of the stainless steel composite bridge deck and the assembly positions of the unit components determined in step S2, the T-shaped fish belly crossbeam is first installed on the stainless steel composite bridge deck, and then the T-shaped rib is assembled by passing it through the reserved holes of the T-shaped fish belly crossbeam.

[0018] Further, in step S4, the web of the T-shaped fish-belly crossbeam is first initially fixed to the stainless steel composite bridge deck by spot welding, then the T-shaped rib is initially fixed to the stainless steel composite bridge deck by spot welding, and then the web of the T-shaped fish-belly crossbeam and the stainless steel composite bridge deck are fully penetrated welded together, with the welding direction from the middle of the web of the T-shaped fish-belly crossbeam to both ends; next, the web of the T-shaped fish-belly crossbeam and the web of the T-shaped rib are welded together, with the welding direction from bottom to top; finally, the fillet weld of the web of the T-shaped rib and the stainless steel composite bridge deck is welded together, with the welding sequence from the middle T-shaped rib to both sides, and the welding direction from the T-shaped fish-belly crossbeam to both ends of the T-shaped rib.

[0019] Furthermore, the welding parameters are as follows: multiple layers and multiple passes, low current, the length of the spot weld is 50mm-100mm, the T-shaped rib corner weld is 2 layers and 3 passes, the welding current is 250A±10A, the weld width is not greater than 14mm, and no additional plates or supports are required during the welding process.

[0020] Furthermore, step S5 includes: after the stainless steel composite bridge deck is welded as a whole, it is flipped over with the stainless steel side facing up. Using the center of the thickness of the T-shaped fish belly crossbeam as a reference, the standard length line and bevel line of the stainless steel composite bridge deck block are drawn to both sides. The width of the block is based on the center of the web of the middle T-shaped rib. Plasma cutting technology is used for cutting. When cutting the two ends of the T-shaped fish belly crossbeam, the crossbeam needs to be adjusted to be horizontal and vertical lines are drawn. After cutting, the bevel surface is ground to 0.2mm-0.4mm using an angle grinder.

[0021] The beneficial effects of this invention are: no need for anti-deformation or rigid fixing jigs; no need for post-weld heat straightening or mechanical straightening; and the correct welding process effectively controls the welding deformation of the bridge deck panels, achieving the technical requirements and obtaining excellent results. In actual manufacturing and processing, it saves a significant amount of tooling materials, manpower, and processing efficiency for controlling deformation, truly achieving energy saving, labor reduction, efficiency improvement, and cost reduction. It can serve as a reference for the manufacturing and processing of bridge deck units for similar steel structure bridges. Attached Figure Description

[0022] Figure 1 This is a flowchart of the process for reducing the deformation of stainless steel composite bridge deck panels during assembly in Example 1. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0024] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0025] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0026] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0027] In the description of the embodiments of the present invention, it should be noted that the indicated orientation or positional relationship is based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the invention is in use, or the orientation or positional relationship commonly understood by those skilled in the art, or the orientation or positional relationship commonly used when the product of the invention is in use. These are only for the convenience of describing the present invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first" and "second" are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0028] In the description of the embodiments of the present invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the present invention based on the specific circumstances. The accompanying drawings in the embodiments are used to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0029] Example 1:

[0030] The process flow for reducing welding deformation of stainless steel composite bridge deck panels in this embodiment is as follows: Figure 1 As shown, the first step is to fabricate the assembly platform. Simultaneously, while fabricating the stainless steel composite bridge deck panel welding platform, the T-shaped fish-belly crossbeams and T-shaped ribs are machined and welded as individual units, with a weld leg of 12mm. After the individual units pass inspection, the bridge deck panels are assembled.

[0031] S1: Assembly Platform Construction

[0032] 1) The assembly platform is made of steel sections welded in a lattice structure to ensure sufficient rigidity, and the pre-camber of the bridge deck width direction is adjusted by the toothed plate to 10mm. Only the platform is made, and no other auxiliary tooling equipment is required.

[0033] 2) Lay a 20mm steel plate on the toothed plate, ensuring a 10mm camber and a longitudinal flatness of less than 1mm, and fix it by spot welding around the perimeter;

[0034] 3) Draw the center baseline at both ends in the longitudinal direction to locate the center line of the stainless steel composite plate.

[0035] S2: Determine the assembly location of unit components

[0036] Before the stainless steel composite panel is placed on the plate, mark the assembly positions of the unit T-shaped fish belly crossbeams, T-shaped ribs, and center lines at both ends on the base side, which will facilitate assembly and plate positioning.

[0037] S3: Stainless steel composite bridge deck and component assembly

[0038] Place the stainless steel composite bridge panel with the base layer side facing up on the assembly platform, and align the center reference lines of both longitudinal ends of the stainless steel composite bridge panel with the center reference lines of both ends of the assembly platform.

[0039] According to the center lines at both ends of the stainless steel composite bridge deck and the assembly positions of the unit components determined in step (b) above, first install the T-shaped fish belly crossbeam on the stainless steel composite bridge deck, and then assemble the T-shaped rib through the reserved holes of the T-shaped fish belly crossbeam.

[0040] S4: Welding

[0041] After the T-shaped ribs are assembled by passing them through the reserved holes of the T-shaped fish belly beam, the T-shaped fish belly beam and the T-ribs are spot welded to the panel one after another. The weld length is 50mm-100mm. It should be noted that spot welding is not performed between the T-shaped fish belly beam and the T-ribs at this time.

[0042] After assembly, welding can be performed on the tire or off the tire. When welding off the tire, two crossbeams need to be added at both ends of the width and adjusted to be less than 1mm horizontally. Welding should proceed from the middle outwards, first welding the full penetration welds and then the fillet welds. Specifically, first weld the full penetration weld between the web of the T-shaped fish-belly crossbeam and the panel, welding from the middle of the web outwards. Next, weld the weld between the T-shaped fish-belly crossbeam and the web of the T-shaped rib, welding from bottom to top. Finally, weld the fillet weld between the web of the T-rib and the panel, welding from the middle T-rib outwards, welding from the T-shaped fish-belly crossbeam as the starting point towards both ends of the T-rib. Welding parameters are: multi-layer, multi-pass, low current; 2 layers and 3 passes for the T-shaped rib fillet welds. Welding current: 250A±10A, weld width not exceeding 14mm. No additional plates or supports are required during welding.

[0043] S5: Trimming and Beveling

[0044] After the stainless steel composite bridge deck panels are welded as a whole, they are flipped over with the stainless steel side facing up. Using the center of the T-shaped fish-belly crossbeam thickness as a reference, standard length lines and bevel lines are drawn on both sides of the bridge deck panels. The width of the panels is based on the center of the web of the middle T-rib. Plasma cutting is used for cutting. When cutting the two ends of the T-shaped fish-belly crossbeam, the crossbeam needs to be adjusted to be horizontal, and vertical lines must be drawn.

[0045] After cutting, the bevel surface must be ground to 0.2mm-0.4mm using an angle grinder, and the welding spatter and chamfers in other parts of the plate must be cleaned.

[0046] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A process for reducing welding deformation of stainless steel composite bridge deck panels for bridges, characterized in that, Includes the following steps: S1: Assembly platform construction; S2: Determine the assembly location of the unit component; S3: Stainless steel composite bridge deck and unit assembly; The unit component includes a T-shaped fish-belly crossbeam and T-ribs; Place the stainless steel composite bridge panel with the base layer side facing up on the assembly platform, and align the center reference lines of both longitudinal ends of the stainless steel composite bridge panel with the center reference lines of both ends of the assembly platform. According to the center lines at both ends of the stainless steel composite bridge deck and the assembly positions of the unit components determined in step S2, first install the T-shaped fish belly crossbeam on the stainless steel composite bridge deck, and then assemble the T-shaped rib through the reserved holes of the T-shaped fish belly crossbeam. S4: Welding; First, the web of the T-shaped fish-belly crossbeam is initially fixed to the stainless steel composite bridge deck by spot welding, and then the T-shaped rib is initially fixed to the stainless steel composite bridge deck by spot welding. Then, the web of the T-shaped fish belly beam and the stainless steel composite bridge deck are fully penetrated welded together, with the welding direction from the middle of the web of the T-shaped fish belly beam to both ends. Next, weld the web weld between the T-shaped fish belly crossbeam and the T-shaped rib, with the welding direction from bottom to top; Finally, the web of the T-rib is welded to the stainless steel composite bridge deck fillet weld. The welding sequence is from the middle T-rib to both sides, and the welding direction is from the T-shaped fish belly crossbeam to both ends of the T-rib. The welding parameters are: multiple layers and multiple passes, low current, the length of the spot weld is 50mm-100mm, the T-shaped rib corner weld is 2 layers and 3 passes, the welding current is 250A±10A, the weld width is no more than 14mm, and no additional plates or supports are required during the welding process. S5: Trimming and beveling; After the stainless steel composite bridge deck is welded as a whole, it is flipped over with the stainless steel side facing up. Using the center of the thickness of the T-shaped fish belly crossbeam as a reference, the standard length line and bevel line of the stainless steel composite bridge deck block are drawn to both sides. The width of the block is based on the center of the web of the middle T-shaped rib. Plasma cutting technology is used for cutting. When cutting the two ends of the T-shaped fish belly crossbeam, the crossbeam needs to be adjusted to be horizontal and vertical lines are drawn. After cutting, the bevel surface is ground to 0.2mm-0.4mm using an angle grinder.

2. The process for reducing welding deformation of stainless steel composite bridge deck panels for bridges according to claim 1, characterized in that, In step S1, the assembly platform is made of steel sections welded in a lattice structure, and the bridge deck pre-camber is adjusted by a toothed plate to 10mm. A center reference line is drawn at both ends of the longitudinal direction of the assembly platform to locate the center line of the stainless steel composite bridge deck.

3. The process for reducing welding deformation of stainless steel composite bridge deck panels for bridges according to claim 2, characterized in that, A 20mm thick steel plate is laid on the toothed plate, ensuring a 10mm camber. The longitudinal flatness of the steel plate is less than 1mm. The steel plate is then spot-welded to the toothed plate.

4. The process for reducing welding deformation of stainless steel composite bridge deck panels for bridges according to claim 3, characterized in that, In step S2, the center lines at both ends of the stainless steel composite bridge deck and the assembly positions of the unit components are drawn on the stainless steel composite bridge deck.

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