A processing technology for controlling sand box welding deformation

Abstract

The present application belongs to the technical field of steel structure assembly welding process, and relates to a processing technology for controlling sand box welding deformation, comprising the steps of blanking, groove processing, rib plate assembly, rib plate welding, sand box overall assembly and sand box overall welding. First, the connecting fillet weld between rib plate one, rib plate two and rib plate three is welded, and then the connecting fillet weld between rib plate one, rib plate two, rib plate three and wall plate is welded. Rib plate one, rib plate two and rib plate three are all welded to form a wall plate assembly. The wall plate assembly is assembled in a clockwise direction. The perpendicularity of the wall plate and the platform is measured in time during the assembly process. After all the wall plate assemblies are assembled, the symmetric welding method is adopted for welding. By reasonably controlling the welding methods and sequences of the wall plates and the rib plates, the wall plate bending degree after the sand box welding can meet the design requirements. The time for completing the assembly and welding of the sand box is shortened from 3 days to 2 days, the construction cost is saved, the construction period is shortened, and the welding efficiency and welding quality are improved.

Description

Technical Field

[0001] This invention belongs to the technical field of steel structure assembly and welding technology, specifically relating to a processing technology for controlling the welding deformation of sand boxes. Background Technology

[0002] Sand boxes are molds used for casting equipment bodies. They come in various sizes, typically square, rectangular, or octagonal. The sand box walls are made of 30mm thick steel plates, the stiffening plates are 40mm and 30mm thick, the lifting lugs are 100mm thick, and the upper and lower cover plates (the cover plates are in the form of a grid) are 30mm thick. The material is Q235B. Due to the relatively thick plates used, welding is difficult and requires a large amount of welding.

[0003] The traditional assembly and welding process for sandboxes involves welding after all panels are assembled. This method allows for maximum control over deformation and ensures overall quality after welding. However, overall welding increases welding time, the number of times the sandbox needs to be flipped, manufacturing costs, and safety risks. The current assembly and welding process has been changed to welding individual panels first, then assembling them into quadrilaterals or octagons. This increases welding efficiency by one-third and significantly improves welding quality. The main challenge in individual panel welding is controlling welding deformation. The flatness of the sandbox wall panels must be controlled within ±5mm. Incorrect welding sequence can cause significant bending, exceeding the sandbox design requirements. Summary of the Invention

[0004] The purpose of this invention is to provide a processing technology for controlling the deformation of sand box welding with a short construction cycle and high welding efficiency.

[0005] The technical solution adopted by this invention to solve its technical problem is: a processing technology for controlling the deformation of sand box welding, comprising the following steps:

[0006] 1) Cutting: Cut the steel plate into several wall panels, stiffener plate one, stiffener plate two, and stiffener plate three that meet the size requirements of the drawings;

[0007] 2) Beveling: After the material is cut, beveling is performed on the ends of the wall panel, stiffener 1 and stiffener 2 respectively;

[0008] 3) Rib assembly: Lay the wall panel flat and draw the positioning lines for rib 1, rib 2, and rib 3 on the wall panel. First, assemble the two rib 1s located on both sides of the wall panel and the rib 2 located in the middle of the wall panel by spot welding. After spot welding, measure the verticality of rib 1 and rib 2. Then, starting from one end of the wall panel, assemble several rib 3s longitudinally between rib 1 and rib 2 by spot welding, and measure the distance between adjacent rib 3s in time.

[0009] 4) Rib Plate Welding: First, weld the fillet welds connecting rib plate 1, rib plate 2, and rib plate 3. When welding, weld one weld every other weld, and so on, until all the fillet welds connecting rib plate 1, rib plate 2, and rib plate 3 are welded in the first pass. Then weld the second and third passes, with the welding sequence being the same as the first pass. Next, weld the fillet welds connecting rib plate 1, rib plate 2, and rib plate 3 to the wall panel. When welding, weld two welds in each square, and weld one square every other square, ensuring even heat distribution. After the first two welds in each square are completed, weld the remaining welds, with the welding sequence being the same as above. Once all rib plate 1, rib plate 2, and rib plate 3 are welded, the wall panel assembly is formed. Measure the flatness of the wall panel, check the appearance quality of the welds, and weld several wall panel assemblies as needed. After passing the inspection, proceed to the next process: overall assembly of the sand box.

[0010] 5) Sandbox assembly: After the wall panel components are welded, a platform is erected, and the layout is marked according to the drawings. The wall panel components are assembled in a clockwise direction. During the assembly process, the verticality between the wall panel and the platform should be measured in time, and the gap of the connecting weld between adjacent wall panel components should be checked. After all wall panel components are assembled, the inner diameter is measured. Welding can begin after the inner diameter is qualified.

[0011] 6) Overall welding of the sand box: After the overall assembly is completed, welding begins. After all welding is completed, the geometric dimensions of the sand box are measured and the overall appearance quality is checked.

[0012] Specifically, in step 1), the wall panel and stiffener three are rectangular, and stiffener one and stiffener two are isosceles trapezoids.

[0013] Specifically, in step 1), the ratio of oxygen to acetylene and the distance from the nozzle to the workpiece should be adjusted in a timely manner during material feeding to ensure that the cutting temperature on both sides is the same and to avoid cutting deformation.

[0014] Specifically, in step 2), the bevel angle is 60°±2°, the bevel type is an X-shaped bevel, and the blunt edge thickness is 1~2mm.

[0015] Specifically, in step 3), during spot welding, the flat seams of the fillet welds connecting stiffener plate 1, stiffener plate 2, and stiffener plate 3 to the wall panel are spot welded, and the vertical seams of the fillet welds connecting stiffener plate 3 to stiffener plate 1 and stiffener plate 2 are spot welded.

[0016] Specifically, the grid in step 4) is a square structure formed by two adjacent stiffeners three and stiffeners one and two on both sides.

[0017] Specifically, in step 5), the gap of the connection weld between adjacent wall panel assemblies is inspected as follows:

[0018] a. Inspect the gap of the weld joints between adjacent wall panel assemblies;

[0019] b. Inspect the gap of the connection weld between stiffener plate 1 and stiffener plate 1 at the corresponding positions of adjacent wall panel components;

[0020] c. Inspect the gap of the connection weld between stiffener plate 2 and stiffener plate 2 of adjacent wall panel components.

[0021] Specifically, the overall welding method of the sand box in step 6) is as follows: a symmetrical welding method is used to weld from the inside to the outside. First, weld the vertical weld between the wall panels of the adjacent wall panel components. Then, weld the butt weld between the first stiffener plate and the second stiffener plate of the adjacent wall panel components at the corner. Next, weld the fillet weld between the first stiffener plate, the second stiffener plate and the wall panel. Finally, install and weld the remaining third stiffener plate. The welding process should be carefully checked to avoid missing welds.

[0022] The present invention has the following beneficial effects: By reasonably controlling the welding method and sequence of each wall panel and stiffener, the bending degree of the wall panel can meet the design requirements after the sand box is welded. The time for completing the assembly and welding of the sand box is shortened from 3 days to 2 days, which improves welding efficiency and welding quality, saves construction costs, and shortens the construction cycle. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the wall panel structure of the present invention.

[0024] Figure 2 This is a schematic diagram of the structure of the first stiffener of the present invention.

[0025] Figure 3 This is a schematic diagram of the front view structure of the wall panel assembly of the present invention.

[0026] Figure 4 This is the present invention. Figure 3 Sectional view along line AA.

[0027] Figure 5 This is a top view of the octagonal sand box after it has been assembled and welded as a whole in Embodiment 1 of the present invention.

[0028] In the diagram, 1 is the wall panel, 2 is the first stiffener, 3 is the second stiffener, and 4 is the third stiffener. Detailed Implementation

[0029] The following are specific embodiments of the present invention, which further describe the technical solution of the present invention. However, the scope of protection of the present invention is not limited to these embodiments. All changes or equivalent substitutions that do not depart from the concept of the present invention are included within the scope of protection of the present invention.

[0030] Example 1

[0031] Taking an octagonal sand box as an example, a processing technology for controlling welding deformation of the sand box includes the following steps:

[0032] 1) Material Cutting: For irregularly shaped parts, controlling the geometric dimensions is crucial. The steel plate is cut into several panels (1, 2, 3, 4) that meet the dimensions specified in the drawings; for example... Figure 1 , 2 As shown, wall panel 1 and stiffener 3 4 are rectangular, while stiffener 1 2 and stiffener 2 3 are isosceles trapezoids. When cutting, the ratio of oxygen to acetylene and the distance from the cutting nozzle to the cutting part should be adjusted in time to ensure that the cutting temperature on both sides is the same and to avoid cutting deformation.

[0033] 2) Beveling: After the material is cut, beveling is performed on the ends of wall panel 1, stiffener 1 2 and stiffener 2 3 respectively. The beveling angle is 60°±2°, the beveling form is X-type beveling, and the blunt edge thickness is 1~2mm.

[0034] 3) Rib Plate Assembly: Lay wall panel 1 flat. Draw positioning lines for rib plate 1 (2), rib plate 2 (3), and rib plate 3 (4) on wall panel 1. First, assemble the two rib plates 1 (2) located on both sides of wall panel 1 and the rib plate 2 (3) located in the middle of wall panel 1 horizontally by spot welding. After spot welding, measure the perpendicularity of rib plates 1 (2) and rib plate 2 (3). Then, starting from one end of wall panel 1, assemble several rib plates 3 (4) vertically between rib plates 1 (2) and rib plate 2 (3) by spot welding, measuring the distance between adjacent rib plates 3 (4) in a timely manner. When spot welding, try to spot weld the flat seams of the fillet welds connecting rib plates 1 (2), rib plate 2 (3), and rib plate 3 (4) to wall panel 1, and spot weld the vertical seams of the fillet welds connecting rib plate 3 (4) to rib plates 1 (2) and rib plate 2 (3). Do not spot weld the ends of the fillet welds connecting rib plates 1 (2) and rib plate 2 (3) to rib plate 3 (4) to avoid stress concentration during welding, which may cause weld cracking.

[0035] 4) Stiffener welding: The main difficulty is controlling deformation when welding the fillet welds connecting wall panel 1 with stiffeners 1, 2, 3, and 4. Wall panel 1 is prone to lateral bending. The welding method adopted is as follows: First, weld the fillet welds connecting stiffeners 1, 2, 3 and 4. Weld every other weld, and so on, to complete the first round of welding of all fillet welds connecting stiffeners 1, 2, 3 and 4. Then weld the second and third rounds, with the welding sequence being the same as the first round. Then weld the fillet welds connecting stiffeners 1, 2, 3 and 4 with wall panel 1. The square structure formed by two adjacent stiffening plates 3 and 4, along with stiffening plates 1 and 2 on each side, constitutes a grid. During welding, two welds are made in each grid, and every other grid is welded to ensure even heat distribution. After the first two welds of each grid are completed, the remaining welds are then welded, following the same welding sequence. Once all stiffening plates 1 and 2, stiffening plates 2 and 3 and stiffening plates 3 are welded, the resulting structure is as follows: Figure 3 , 4 For the wall panel assembly shown, measure the flatness of wall panel 1, check the appearance quality of the weld, weld several wall panel assemblies as needed, and after passing the inspection, proceed to the next process of overall assembly of the sand box.

[0036] 5) Sandbox assembly: After the wall panel components are welded, a platform is erected, and the layout is marked according to the drawings. The wall panel components are assembled in a clockwise direction. During the assembly process, the verticality of wall panel 1 to the platform should be measured in time. The gap of the connecting weld between wall panel 1 and wall panel 1 of adjacent wall panel components should be checked. The gap of the connecting weld between stiffener 1 2 and stiffener 2 2 of adjacent wall panel components should be checked. The gap of the connecting weld between stiffener 2 3 and stiffener 2 3 of adjacent wall panel components should be checked. After all wall panel components are assembled, the inner diameter is measured. Welding begins after the inner diameter is qualified.

[0037] 6) Overall Welding of the Sand Box: After the overall assembly is completed, welding begins. A symmetrical welding method is used, welding from the inside out. First, weld the vertical welds connecting wall panels 1 to 1 of adjacent wall panel components. Then, weld the butt welds between stiffeners 1 and 2 at the corresponding positions of adjacent wall panel components at the corners, as well as the butt welds between stiffeners 2 and 3 of adjacent wall panel components. Next, weld the fillet welds connecting stiffeners 1 and 2 and 3 to wall panel 1. Finally, install and weld the remaining stiffener 3 and 4 at the corners connecting wall panels 1 to 1 of adjacent wall panel components. Careful inspection is required during the welding process to avoid missed welds. All welding is complete as follows: Figure 5 As shown, measure the geometric dimensions of the sand box and check the overall appearance quality.

[0038] Example 2

[0039] The assembly and welding control process of the quadrilateral sand box only requires cutting the steel plate according to the size requirements of the drawing, and the subsequent process operation is the same as in Example 1.

[0040] This invention is not limited to the above-described embodiments. Anyone should know that any structural changes made under the guidance of this invention, and any technical solutions that are the same as or similar to this invention, fall within the protection scope of this invention.

[0041] The technologies, shapes, and structures not described in detail in this invention are all known technologies.

Claims

1. A processing technology for controlling welding deformation of sand boxes, characterized in that, Includes the following steps: 1) Cutting: Cut the steel plate into several wall panels, stiffener plate one, stiffener plate two, and stiffener plate three that meet the size requirements of the drawings; 2) Beveling: After the material is cut, beveling is performed on the ends of the wall panel, stiffener 1 and stiffener 2 respectively; 3) Rib assembly: Lay the wall panel flat and draw the positioning lines for rib 1, rib 2, and rib 3 on the wall panel. First, assemble the two rib 1s located on both sides of the wall panel and the rib 2 located in the middle of the wall panel by spot welding. After spot welding, measure the verticality of rib 1 and rib 2. Then, starting from one end of the wall panel, assemble several rib 3s longitudinally between rib 1 and rib 2 by spot welding, and measure the distance between adjacent rib 3s in time. 4) Rib Plate Welding: First, weld the fillet welds connecting rib plate 1, rib plate 2, and rib plate 3. When welding, weld one weld every other weld, and so on, until all the fillet welds connecting rib plate 1, rib plate 2, and rib plate 3 are welded in the first pass. Then weld the second and third passes, with the welding sequence being the same as the first pass. Next, weld the fillet welds connecting rib plate 1, rib plate 2, and rib plate 3 to the wall panel. When welding, weld two welds in each square, and weld one square every other square, ensuring even heat distribution. After the first two welds in each square are completed, weld the remaining welds, with the welding sequence being the same as above. Once all rib plate 1, rib plate 2, and rib plate 3 are welded, the wall panel assembly is formed. Measure the flatness of the wall panel, check the appearance quality of the welds, and weld several wall panel assemblies as needed. After passing the inspection, proceed to the next process: overall assembly of the sand box. 5) Sandbox assembly: After the wall panel components are welded, a platform is erected, and the layout is marked according to the drawings. The wall panel components are assembled in a clockwise direction. During the assembly process, the verticality between the wall panel and the platform should be measured in time, and the gap of the connecting weld between adjacent wall panel components should be checked. After all wall panel components are assembled, the inner diameter is measured. Welding can begin after the inner diameter is qualified. 6) Overall welding of the sand box: After the overall assembly is completed, welding begins. After all welding is completed, the geometric dimensions of the sand box are measured and the overall appearance quality is checked.

2. The processing technology for controlling welding deformation of sand boxes as described in claim 1, characterized in that, In step 1), the wall panel and stiffener three are rectangular, and stiffener one and stiffener two are isosceles trapezoids.

3. The processing technology for controlling welding deformation of sand boxes as described in claim 1 or 2, characterized in that, In step 1), the ratio of oxygen to acetylene and the distance between the nozzle and the workpiece should be adjusted in time during material feeding to ensure that the cutting temperature on both sides is the same and to avoid cutting deformation.

4. The processing technology for controlling welding deformation of sand boxes as described in claim 1, characterized in that, In step 2), the bevel angle is 60°±2°, the bevel type is X-shaped bevel, and the blunt edge thickness is 1~2mm.

5. The processing technology for controlling welding deformation of the sand box as described in claim 1, characterized in that, In step 3), during spot welding, the flat seams of the fillet welds connecting stiffener plate 1, stiffener plate 2, and stiffener plate 3 to the wall panel are spot welded, and the vertical seams of the fillet welds connecting stiffener plate 3 to stiffener plate 1 and stiffener plate 2 are spot welded.

6. The processing technology for controlling welding deformation of sand boxes as described in claim 1, characterized in that, The grid in step 4) is a square structure formed by two adjacent stiffeners (three) and stiffeners (one and two) on both sides.

7. The processing technology for controlling welding deformation of sand boxes as described in claim 1, characterized in that, In step 5), the specific inspection of the weld gap between adjacent wall panel assemblies is as follows: a. Inspect the gap of the weld joints between adjacent wall panel assemblies; b. Inspect the gap of the connection weld between stiffener plate 1 and stiffener plate 1 at the corresponding positions of adjacent wall panel components; c. Inspect the gap of the connection weld between stiffener plate 2 and stiffener plate 2 of adjacent wall panel components.

8. The processing technology for controlling welding deformation of sand boxes as described in claim 1, characterized in that, The overall welding method of the sand box in step 6) is as follows: The symmetrical welding method is used to weld from the inside to the outside. First, weld the vertical weld between the wall panels of the adjacent wall panel components. Then, weld the butt weld between the first stiffener plate and the second stiffener plate of the adjacent wall panel components at the corner. Then, weld the fillet weld between the first stiffener plate, the second stiffener plate and the wall panel. Finally, install and weld the remaining third stiffener plate. The welding process should be carefully checked to avoid missing welds.

Images