A method for manufacturing a low-pressure inner-cylinder special-shaped component

Abstract

The application provides a low-pressure inner cylinder special-shaped component manufacturing method, and belongs to the field of manufacturing welding. The method and tooling ensure the assembly size of the special-shaped component, solve the problem of complex special-shaped component development and design, control welding deformation, and the special-shaped component is welded to the inner cylinder to meet the drawing requirements.

Description

Technical Field

[0001] This invention relates to the field of steam turbine technology, and specifically to a method for manufacturing irregularly shaped components for a low-pressure inner cylinder. Background Technology

[0002] The irregularly shaped inner cylinder component is assembled from a steam flange, cylinder, side plates, and branch pipes by welding. The branch pipes intersect with the cylinder, and the side plates are obliquely embedded in the cylinder. The bottom surface of the irregularly shaped component intersects with the arc surface of the inner cylinder. The cylinder, side plates, and branch pipes are all made of 50mm steel plates. The unfolding and layout of the thick-plate irregularly shaped component presents significant challenges, and the assembly dimensions and welding deformation are difficult to control. Summary of the Invention

[0003] The purpose of this invention is to provide a method for manufacturing irregularly shaped components for low-pressure inner cylinders. This method can effectively solve the problem of unfolding and shaping complex irregularly shaped components, ensure the assembly dimensions of irregularly shaped components, control welding deformation, and ensure that the irregularly shaped components are welded onto the inner cylinder in accordance with the drawing requirements, thus guaranteeing the quality of the components.

[0004] To achieve the above-mentioned technical features, the objective of this invention is as follows: A method for manufacturing a low-pressure inner cylinder irregular-shaped component, comprising the following steps:

[0005] Step 1: Forming the cylinder body:

[0006] The cylinder is cut to its unfolded dimensions to obtain a cylinder sheet, which is then rolled into a cylindrical cylinder.

[0007] Step 2, Assembly and connection of the cylindrical body and the flange:

[0008] The formed cylindrical body is then corrected and assembled onto the flange;

[0009] Step 3: Laying out and opening the cylindrical body;

[0010] Place the cylinder opening template on the outer surface of the cylindrical body, and draw the position lines of the side plate and branch pipe openings on the outer surface of the cylindrical body according to the cylinder opening template; use flame gas cutting to make the openings, thereby forming the side plate openings and branch pipe openings, and use a grinding wheel to polish the cut surface; finally, the structure of the cylinder is formed.

[0011] Step 4, forming the branch pipe:

[0012] The branch pipe is cut to the unfolded size to obtain the branch pipe plate. The branch pipe plate is then pressed into a U-shaped branch pipe using a mold. To facilitate forming, the parts where the branch pipe intersects with the cylinder and the bottom arc surface are not cut off in advance. After the branch pipe is formed and corrected, the outline of the intersecting surface with the cylinder is drawn on the outer surface of the U-shaped branch pipe using a cylinder opening template. The excess part of the branch pipe is removed by flame gas cutting along the line, thereby forming the cylinder connection surface and bottom surface. The cut surface is polished smooth using a grinding wheel.

[0013] Step 5, side panel blanking and forming:

[0014] Cut the side panel to the unfolded size to obtain the side panel material. To facilitate forming, leave at least 150mm forming allowance at the intersection of the side panel material and the bottom arc surface. After the side panel material is formed and corrected, remove the forming allowance and grind the cut surface smooth with a grinding wheel.

[0015] Step Six: Assembly of the cylinder, branch pipes, and side plates:

[0016] The branch pipes and side plates are assembled sequentially at the opening positions of the cylinder;

[0017] Step 7, Fabrication and assembly of process support ribs:

[0018] After the initial assembly is completed, process support ribs are initially installed inside the cylinder, branch pipe and side plate to prevent welding deformation.

[0019] Step 8: Welding and forming of the irregularly shaped components of the low-pressure inner cylinder:

[0020] Gas shielded welding was used to symmetrically weld the initially assembled cylinder, branch pipe and side plate. After welding, the bottom arc pattern line of the bottom arc surface was drawn on the platform. The bottom arc surface of the low-pressure inner cylinder irregular component was corrected according to the line, the process support ribs were removed and polished smooth.

[0021] In step two, during the assembly of the cylinder and flange, the cylindrical body and flange are assembled together on the assembly platform, and the assembly cross center line is drawn.

[0022] In step three, the cross center line is used as a reference to cover the outer surface of the cylindrical body with the cylinder opening template.

[0023] The cylinder opening template is based on the outer contour of the intersection of the cylinder, side plate and branch pipe. The intersection is laid out using both manual layout and UG modeling. After the two methods are verified, the cylinder opening template is determined. The cylinder opening template is divided into two symmetrical halves. Each half is provided with a branch pipe layout hole located in the center and side plate layout holes located on both sides of the branch pipe layout hole.

[0024] In step four, the branch pipe marking template is based on the outer contour of the intersection of the cylinder and the branch pipe. The intersection is laid out using both manual layout and UG modeling. After the two methods are verified against each other, the branch pipe marking template is determined. Laser cutting is used to ensure the accuracy of the template.

[0025] One end of the branch pipe marking template is provided with a cylinder intersection line that matches the cylinder body, and the other end of the branch pipe marking template is provided with a bottom arc line that matches the bottom arc surface.

[0026] In step five, during the side panel forming process, a side panel forming template is used to assist in the forming process. The side panel forming template is an inner card template designed and formed according to the bending angle of the side panel. Laser cutting is used to ensure the accuracy of the template.

[0027] The process support includes a long support rod that is supported between the two branch pipes, and a first short support rod and a second short support rod that are symmetrically arranged are welded and fixed on the long support rod and located between the two side plates.

[0028] The flange is cut into four equal parts with a machining allowance of at least 10mm on each side, welded into a complete circle, passes non-destructive testing, and is then rough-machined before installation.

[0029] The present invention has the following beneficial effects:

[0030] 1. The inner cylinder irregular-shaped component manufactured using this method not only solves the problem of unfolding and patterning complex irregular-shaped components, but also meets the assembly size requirements of thick plate irregular-shaped components, controls welding deformation, and improves work efficiency.

[0031] 2. By using the above-mentioned cylinder opening template, the cylinder can be precisely formed.

[0032] 3. By using the above-mentioned branch pipe marking template, the precise forming of U-shaped branch pipes can be achieved.

[0033] 4. By using the side panel forming template described above, precise forming of the side panel can be achieved.

[0034] 5. By adopting the above-mentioned process of reinforcing bars, deformation during the welding process can be effectively prevented. Attached Figure Description

[0035] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0036] Figure 1 This is a structural diagram of the irregularly shaped components of the low-pressure inner cylinder.

[0037] Figure 2 This is a diagram of the cylinder forming process.

[0038] Figure 3 This is a diagram of the branch pipe forming process.

[0039] Figure 4 This is a diagram of the side panel forming process.

[0040] Figure 5 This is a diagram illustrating the forming process of the flange and cylindrical body.

[0041] Figure 6 This is a preliminary assembly diagram of the flange, branch pipe, cylinder, and side plate.

[0042] Figure 7 Structural diagram for the arrangement of process support ribs.

[0043] Figure 8 This is a diagram showing the formed state of the bottom arc surface.

[0044] Figure 9 This is a structural diagram of the template for opening holes in the cylinder.

[0045] Figure 10 A template structure diagram for marking out branch pipes.

[0046] Figure 11 This is a structural diagram of the side panel forming template.

[0047] In the diagram: 1. Flange; 2. Branch pipe; 3. Cylinder; 4. Side plate; 5. Cylinder plate; 6. Cylindrical cylinder; 7. Branch pipe plate; 8. U-shaped branch pipe; 9. Cylinder connecting surface; 10. Bottom surface; 11. Side plate material; 12. Side plate forming template; 13. Side plate opening; 14. Branch pipe opening; 15. Long support rod; 16. First short support rod; 17. Second short support rod; 18. Bottom arc surface; 19. Cylinder opening template; 20. Side plate layout hole; 21. Branch pipe layout hole; 22. Branch pipe marking template; 23. Cylinder intersection line; 24. Bottom arc line. Detailed Implementation

[0048] The embodiments of the present invention will be further described below with reference to the accompanying drawings.

[0049] Example 1:

[0050] See Figure 1-11 A method for manufacturing a low-pressure inner cylinder irregular-shaped component includes the following steps:

[0051] Step 1, forming the cylinder 3:

[0052] The cylinder 3 is cut to its unfolded dimensions to obtain the cylinder plate 5. The cylinder plate 5 is then rolled into a cylindrical cylinder 6.

[0053] Step 2, Assembly and connection of cylindrical body 6 and flange 1:

[0054] The formed cylindrical body 6 is corrected and then assembled onto the flange 1;

[0055] During the assembly of the cylinder 3 and the flange 1, the cylindrical cylinder 6 and the flange 1 are assembled together on the assembly platform, and the assembly cross center line is drawn; with the cross center line as the reference, the cylinder opening template 19 is placed on the outer surface of the cylindrical cylinder 6.

[0056] The flange 1 is cut into four equal parts with a machining allowance of at least 10mm on each side, welded into a complete circle, passes non-destructive testing, and is ready for installation after rough machining.

[0057] Step 3: Lofting and opening the cylindrical body 6;

[0058] The cylinder opening template 19 is placed on the outer surface of the cylindrical cylinder 6. The opening positions of the side plate 4 and the branch pipe 2 are drawn on the outer surface of the cylindrical cylinder 6 according to the cylinder opening template 19. The openings are made by flame cutting according to the lines, thereby forming the side plate opening 13 and the branch pipe opening 14. The cut surfaces are polished smooth by grinding wheel. Finally, the structure of the cylinder 3 is formed.

[0059] The cylinder opening template 19 is based on the outer contour of the intersection of the cylinder 3, the side plate 4, and the branch pipe 2. The intersection is laid out using both manual layout and UG modeling methods. After mutual verification, the cylinder opening template 19 is determined. The cylinder opening template 19 is divided into two symmetrical halves. Each half is provided with a branch pipe layout hole 21 located in the center and side plate layout holes 20 located on both sides of the branch pipe layout hole 21.

[0060] Step 4, forming the branch pipe 2:

[0061] The branch pipe 2 is cut to the unfolded size to obtain the branch pipe plate 7. The branch pipe plate 7 is pressed into a U-shaped branch pipe 8 using a mold. To facilitate the forming, the parts where the branch pipe 2 intersects with the cylinder 3 and the bottom arc surface 18 are not cut off in advance. After the branch pipe 2 is formed and corrected, the cylinder opening template 19 is used to draw the outline of the intersecting surface with the cylinder 3 on the outer surface of the U-shaped branch pipe 8. The excess part of the branch pipe is removed by flame gas cutting along the line, thereby forming the cylinder connecting surface 9 and the bottom surface 10. The cut surface is polished smooth by a grinding wheel.

[0062] Among them, the branch pipe marking template 22 is based on the outer contour of the intersection of the cylinder 3 and the branch pipe 2. The intersection is laid out using both manual layout and UG modeling. After mutual verification, the branch pipe marking template 22 is determined. Laser cutting is used to ensure the accuracy of the template.

[0063] Furthermore, one end of the branch pipe marking template 22 is provided with a cylinder intersecting line 23 that matches the cylinder body 3, and the other end of the branch pipe marking template 22 is provided with a bottom arc line 24 that matches the bottom arc surface 18.

[0064] Step 5, forming the side panel 4:

[0065] Cut the side plate 4 according to the unfolded size to obtain the side plate material 11. To facilitate forming, leave at least 150mm forming allowance at the intersection of the side plate material 11 and the bottom arc surface 18. After the side plate material 11 is formed and corrected, remove the forming allowance and grind the cut surface smooth with a grinding wheel.

[0066] During the forming process of the side plate material 11, a side plate forming template 12 is used to assist in the forming process. The side plate forming template 12 is an inner card template designed and formed according to the bending angle of the side plate. Laser cutting is used to ensure the accuracy of the template.

[0067] Step 6: Assembly of cylinder 3, branch pipe 2, and side plate 4:

[0068] The branch pipe 2 and the side plate 4 are assembled sequentially at the opening position of the cylinder 3;

[0069] Step 7, Fabrication and assembly of process support ribs:

[0070] After the initial assembly is completed, process support ribs are initially installed inside the cylinder 3, branch pipe 2 and side plate 4 to prevent welding deformation.

[0071] The process support includes a long support rod 15 supported between the two branch pipes 2, and a first short support rod 16 and a second short support rod 17 symmetrically arranged are welded and fixed on the long support rod 15 and located between the two side plates 4.

[0072] Step 8: Welding and forming of the irregularly shaped components of the low-pressure inner cylinder:

[0073] Gas shielded welding was used to symmetrically weld the initially assembled cylinder 3, branch pipe 2 and side plate 4. After welding, the bottom arc surface 18 of the bottom arc surface was drawn on the platform. The bottom arc surface 18 of the low-pressure inner cylinder irregular component was corrected according to the line, the process support ribs were removed, and the surface was polished smooth.

[0074] Example 2:

[0075] Take the fabrication of irregularly shaped components for the XMSL inner cylinder as an example.

[0076] 1. Based on the structural type and dimensions of the irregularly shaped components of the XMSL inner cylinder, a template for cylinder opening, a template for branch pipe marking, and a template for side plate forming were designed and manufactured. Process support ribs were also designed and manufactured.

[0077] 2. Parts preparation: Flanges, cylinders, side plates and branch pipes were prepared according to the above method.

[0078] 3. Assemble the cylinder onto the flange, and use a cylinder opening template to draw intersecting opening lines on the outer surface of the cylinder. Use flame cutting to make the openings, and then grind the cut surfaces smooth with an abrasive wheel.

[0079] 4. Assemble the branch pipes and side plates in sequence. And assemble the process support ribs inside the irregularly shaped components.

[0080] 5. Perform symmetrical welding using CO2 gas shielded welding. After welding, draw a bottom arc pattern on the platform and correct the bottom arc surface of the irregular component according to the pattern. Remove the support ribs and grind smooth.

[0081] 6. The XMSL inner cylinder irregular component manufactured using the above method and tooling has been inspected and its dimensions fully meet the requirements of the drawings.

Claims

1. A method for manufacturing irregularly shaped components for a low-pressure inner cylinder, characterized in that, Includes the following steps: Step 1, forming the cylinder (3): The cylinder (3) is cut to the unfolded size to obtain the cylinder plate (5), and the cylinder plate (5) is rolled into a cylindrical cylinder (6). Step 2, Assembly and connection of the cylindrical body (6) and flange (1): The formed cylindrical body (6) is corrected and then assembled onto the flange (1); Step 3, laying out and opening the cylindrical body (6); Place the cylinder opening template (19) on the outer surface of the cylindrical body (6), and draw the opening positions of the side plate (4) and the branch pipe (2) on the outer surface of the cylindrical body (6) according to the cylinder opening template (19); use flame gas cutting to open the holes according to the lines, thereby forming the side plate opening (13) and the branch pipe opening (14), and use a grinding wheel to polish the cut surface; finally, the structure of the cylinder (3) is formed. Step 4, forming the branch pipe (2): Cut the branch pipe (2) according to the unfolded size to obtain the branch pipe plate (7). Press the branch pipe plate (7) into a U-shaped branch pipe (8) using a mold. To facilitate the forming, the part where the branch pipe (2) intersects with the cylinder (3) and the bottom arc surface (18) is not cut off in advance. After the branch pipe (2) is formed and corrected, the outline of the intersecting surface with the cylinder (3) is drawn on the outer surface of the U-shaped branch pipe (8) using the branch pipe marking template (22). The excess part of the branch pipe is removed by flame gas cutting according to the line, thereby forming the cylinder connecting surface (9) and the bottom surface (10). The cut surface is polished smooth by a grinding wheel. Step 5, blanking and forming of side panel (4): Cut the side plate (4) according to the unfolded size to obtain the side plate material (11). To facilitate forming, leave at least 150mm forming allowance at the intersection of the side plate material (11) and the bottom arc surface (18). After the side plate material (11) is formed and corrected, remove the forming allowance and grind the cut surface smooth with a grinding wheel. Step 6: Assembly of the cylinder (3) with the branch pipe (2) and side plate (4): The branch pipe (2) and the side plate (4) are assembled sequentially at the opening position of the cylinder (3); Step 7, Fabrication and assembly of process support ribs: After the initial assembly is completed, process support ribs are initially installed inside the cylinder (3), branch pipe (2) and side plate (4) to prevent welding deformation; Step 8: Welding and forming of the irregularly shaped components of the low-pressure inner cylinder: Gas shielded welding was used to symmetrically weld the initially assembled cylinder (3), branch pipe (2) and side plate (4). After welding, the bottom arc surface (18) of the bottom arc surface (18) was drawn on the platform. The bottom arc surface (18) of the low-pressure inner cylinder irregular component was corrected according to the line. The process support ribs were removed and polished smooth.

2. The method for manufacturing a low-pressure inner cylinder irregular-shaped component according to claim 1, characterized in that: In step two, during the assembly of the cylinder (3) and flange (1), the cylindrical cylinder (6) and flange (1) are assembled together on the assembly platform, and the assembly cross center line is drawn. In step three, the cross center line is used as a reference, and the cylinder opening template (19) is placed on the outer surface of the cylindrical body (6).

3. The method for manufacturing a low-pressure inner cylinder irregular-shaped component according to claim 2, characterized in that: The cylinder opening template (19) is based on the outer contour of the intersection of the cylinder (3), the side plate (4), and the branch pipe (2). The intersection is laid out using both manual layout and UG modeling. After mutual verification, the cylinder opening template (19) is determined. The cylinder opening template (19) is divided into two symmetrical halves. Each half is provided with a branch pipe layout hole (21) located in the center and side plate layout holes (20) located on both sides of the branch pipe layout hole (21).

4. The method for manufacturing a low-pressure inner cylinder irregular-shaped component according to claim 1, characterized in that: In step four, the branch pipe marking template (22) is based on the outer contour of the intersection of the cylinder (3) and the branch pipe (2). The intersection is laid out using both manual layout and UG modeling. After the two methods are verified, the branch pipe marking template (22) is determined. Laser cutting is used to ensure the accuracy of the template.

5. The method for manufacturing a low-pressure inner cylinder irregular-shaped component according to claim 4, characterized in that: One end of the branch pipe marking template (22) is provided with a cylinder intersection line (23) that matches the cylinder (3), and the other end of the branch pipe marking template (22) is provided with a bottom arc line (24) that matches the bottom arc surface (18).

6. The method for manufacturing a low-pressure inner cylinder irregular-shaped component according to claim 1, characterized in that: In step five, during the forming process of the side plate material (11), a side plate forming template (12) is used to assist in the forming process. The side plate forming template (12) is an inner card template designed and formed according to the bending angle of the side plate. Laser cutting is used to ensure the accuracy of the template.

7. The method for manufacturing a low-pressure inner cylinder irregular-shaped component according to claim 1, characterized in that: The process support includes a long support rod (15) supported between the two branch pipes (2), and a first short support rod (16) and a second short support rod (17) are welded and fixed on the long support rod (15) and located between the two side plates (4).

8. The method for manufacturing a low-pressure inner cylinder irregular-shaped component according to claim 1, characterized in that: The flange (1) is cut into four equal parts with a machining allowance of at least 10mm on each side, welded into a whole circle, and qualified by non-destructive testing. After rough machining, it is ready for installation.

Images