Manufacturing method of thick plate variable cross-section saddle-shaped tubular column

Abstract

The invention relates to the technical field of manufacturing of steel structures, in particular to a manufacturing method of a thick plate variable cross-section saddle-shaped tubular column. Comprising the steps that 1, parts are blanked; 2, reel pipe manufacturing; 3, semicircular pipe forming; fourthly, a jig frame is erected; 5, assembling and welding the semicircular pipe; and 6, assembling and welding the inner partition plate and the remaining parts. The thick plate variable cross-section saddle-shaped tubular column component is summarized, through a scientific steel pipe arc forming mode, a reasonable sectional blanking method and an assembling and welding sequence, it can be accurately guaranteed that the size and welding seam requirements of the thick plate variable cross-section saddle-shaped tubular column component are all qualified, consumption of materials, machines and labor is reduced, the machining period is shortened, and the production efficiency is improved. And the machining quality is improved, and the method for efficiently manufacturing the thick plate variable cross-section saddle-shaped tubular column is achieved.

Description

Technical Field

[0001] The invention relates to the technical field of steel structure manufacturing, in particular to a method for manufacturing a thick plate variable-section saddle-shaped pipe column. Background Art

[0002] With the continuous improvement of living standards, large-scale infrastructure projects continue to increase, and variable-section saddle-shaped support columns are widely used in bridges and public facilities projects. Traditional designs use cast-in-place or prefabricated reinforced concrete columns, but due to the complex shape of the components, the production of special-shaped templates is difficult and costly, and it does not conform to the green and environmentally friendly construction concept. Therefore, it is urgent to invent an efficient production method for thick plate variable-section saddle-shaped columns. Summary of the invention

[0003] The purpose of the present invention is to overcome the above-mentioned defects and to provide a method for manufacturing a thick plate variable-section saddle-shaped pipe column.

[0004] In order to achieve the above object, the present invention is achieved in the following ways: A method for manufacturing a thick plate variable-section saddle-shaped pipe column, comprising: Step 1: Cutting parts; Step 2: Making the coiled tube; Step 3: semicircular tube forming; Step 4: Setting up the tire frame; Step 5: Assemble and weld the semicircular tubes; Step 6: Assemble and weld the inner partition and remaining parts.

[0005] In the method for manufacturing the thick plate variable-section saddle-shaped pipe column, in step 1, the special-shaped rib plate, the bottom plate and the cover plate are cut by a CNC cutting machine; the remaining parts are cut by a semi-automatic cutting machine; and a 30mm margin is left in the length direction of the steel pipe.

[0006] In the method for manufacturing the thick plate variable-section saddle-shaped pipe column, in step 2, a 1,000-ton hydraulic press is used to pre-bend the two ends of the steel plate before rolling the pipe; a CNC plate rolling machine is used to roll the steel pipe.

[0007] In the manufacturing method of the thick plate variable cross-section saddle-shaped pipe column, in step 3, the pipe bending process is hot bending or cold bending, which is reasonably selected according to the thickness and curvature of the steel pipe and the company's own equipment; Among them, the hot bending process is as follows: 1) According to the drawing requirements, material specifications, thickness, and radius, make the corresponding horizontal acceptance platform to inspect the levelness and curvature of the finished material; 2) Make the corresponding operating platform according to the material specifications, thickness and radius to ensure that the material is in the horizontal direction during each bending process; 3) Fix the material: put the material into the equipment, clamp it and lay it flat; 4) Fix the mold: fix the radius rail according to the digital requirements of the drawing, and then fix the mold; 5) Adjust the heating equipment: Check whether the heating equipment, water circuits, and circuits are safe and smooth and can operate normally; 6) Hot bending parameters: medium frequency bending machine power 300kw / h, heating temperature 900 degrees ~ 1000 degrees, advancement speed 10mm / min; 7) After the straight pipe is cut, the bending machine is used to put an induction coil on the part of the steel pipe to be bent, and the pipe head is clamped by a mechanical rotating arm. The medium-frequency current is passed through the induction coil to heat the steel pipe. When the temperature of the steel pipe rises to the plastic state, the rear end of the steel pipe is pushed forward by mechanical thrust to bend it. The bent steel pipe part is quickly cooled by coolant. In this way, the steel pipe is continuously bent while being heated, pushed, bent, and cooled; 8) Product testing: test the product’s appearance, angles and geometric dimensions, ovality, curvature and keep self-inspection records; 9) If the curvature deviation of the bent workpiece is outside the deviation range required by the drawing, the workpiece can be put back on the machine tool and the curvature can be corrected using the hydraulic cylinder until the curvature deviation is within the requirements of the drawing; 10) If the ovality deviation of the bent workpiece is found to be outside the deviation range required by the drawing, which affects the docking interface of the workpiece, the workpiece can be put back on the machine tool and the ovality of the pipe mouth can be corrected using a hydraulic cylinder; 11) After forming, the edge of the semicircular tube will be wavy and needs to be reshaped; The cold bending process is as follows: 1) Selection of bending equipment: plane bending of steel pipes is performed by mechanical cold bending, and the equipment is a hydraulic top bending machine; 2) Design of steel pipe bending jig: Before bending the pipe, a special paving die and a pressing die are made according to the cross-sectional size of the steel pipe. The paving die and the pressing die are made of thick plates. The pressing die is welded to the force transmission device of the top press, and the paving die is welded to the fixing device. The opening size of the paving die and the pressing die is determined according to the test data. During operation, the steel pipe is placed on the paving die, and the top press moves the pressing die to hold the steel pipe tightly. Then the top press transmits force to the steel pipe through the transmission device to bend the steel pipe. When the transmission device of the top press is withdrawn, the steel pipe can move freely, which is very convenient for operation, controlling deformation and ensuring quality, and improving work efficiency. 3) Gradual bending of steel pipe: Use hydraulic oil to bend the steel pipe point by point, from the inner arc point to the outer side; the amount of pressure during bending must be strictly controlled so that there is no obvious die mark. The amount of pressure is calculated according to the curvature radius of the steel pipe. It is generally divided into five times of pressure forming to achieve a smooth transition on the surface of the steel pipe without large wrinkles; 4) Bending inspection: After the bending is completed, check the total chord length L of the bent pipe and the arc height H1, H2, H3, H4... of each bending control point to ensure the overall curvature effect of the bent pipe; the error of the total chord length L of the bent pipe is controlled within 10mm, the error of the arc height of each bending control point is controlled within 10mm, and the ovality deviation of the round tube shall not exceed 5mm.

[0008] The method for making the thick plate variable-section saddle-shaped pipe column is as follows: in step 5, the bent steel pipe is first split and cut into corresponding arc-shaped semicircular pipes along the length direction, and then four arc-shaped semicircular pipes are assembled to the platform and fixed by positioning welding. The arc-shaped steel columns on both sides are divided into two sections, and the triangular plates between the lower arc-shaped pipes are evenly divided on the arc-shaped pipes and processed together, avoiding the problem of concentrated welds caused by separate processing and assembly of the triangular plates, and this segmentation can also avoid cross welds.

[0009] The method for making the thick plate variable-section saddle-shaped pipe column is as follows: in step 6, the internal horizontal and vertical partitions are assembled separately, and the welding with the steel pipe is completed. Finally, the top cover plate of the steel column and the upper side panel of the steel column are assembled. The welding personnel enter the internal welding partition through the hole of the internal partition to weld the connection welds between the steel pipe and the side panel of the steel column. When welding the vertical and horizontal internal partitions, the ventilation measures inside the box should be strengthened, and DC fans should be installed at both ends of the component. The main weld of the outside is welded by semi-automatic submerged arc trolley welding. First, lay the component flat, and set a simple trolley track along the arc direction of the upper panel. Pay attention to the control and adjustment of various parameters during welding. After one side is welded, turn over and weld the main weld of the other side.

[0010] The semicircular wall panels with arcs on both sides, the approximately triangular panel in the middle, and the longitudinal and transverse partitions inside form a variable-section saddle-shaped pipe column. This type of component has a complex appearance and is difficult to manufacture. There is no mature processing technology for this type of component. The cross-sectional dimensions of this type of component processed by most factories currently have large deviations and low processing efficiency. The present invention summarizes that this type of component can accurately ensure that the dimensions and weld requirements of this type of thick plate variable-section saddle-shaped steel column are all qualified through a scientific steel pipe arc forming method, a reasonable segmented cutting method, and an assembly and welding sequence, and reduces material, machinery, and labor consumption, shortens the processing period, and improves the processing quality, thereby realizing a method for efficiently manufacturing thick plate variable-section saddle-shaped pipe columns. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 Schematic diagram of thick plate variable-section saddle-shaped pipe column.

[0012] Figure 2 Schematic diagram of steel plate coil.

[0013] Figure 3 Schematic diagram of the steel tube top bending jig.

[0014] Figure 4Schematic diagram of pipe bending inspection control points.

[0015] Figure 5 Schematic diagram of panel laying on one side of the steel column.

[0016] Figure 6 Schematic diagram of the assembly of four semicircular steel pipes.

[0017] Figure 7 Schematic diagram of the internal transverse partition assembly.

[0018] Figure 8 Schematic diagram of the internal longitudinal partition assembly.

[0019] Fig. 9 Schematic diagram of the assembly of the top partition and upper steel column side panels. DETAILED DESCRIPTION

[0020] The technical solutions of the embodiments of the present application will be described clearly and completely below in conjunction with the accompanying drawings. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field without creative work based on the embodiments in the embodiments of the present application are within the scope of protection requested by the present application.

[0021] like Figures 1 to 9 A method for manufacturing a thick plate variable-section saddle-shaped pipe column, comprising: Step 1: Cutting parts; Step 2: Making the coiled tube; Step 3: semicircular tube forming; Step 4: Setting up the tire frame; Step 5: Assemble and weld the semicircular tubes; Step 6: Assemble and weld the inner partition and remaining parts.

[0022] In the method for manufacturing the thick plate variable-section saddle-shaped pipe column, in step 1, the special-shaped rib plate, the bottom plate and the cover plate are cut by a CNC cutting machine; the remaining parts are cut by a semi-automatic cutting machine; and a 30mm margin is left in the length direction of the steel pipe.

[0023] In the method for manufacturing the thick plate variable-section saddle-shaped pipe column, in step 2, a 1,000-ton hydraulic press is used to pre-bend the two ends of the steel plate before rolling the pipe; a CNC plate rolling machine is used to roll the steel pipe.

[0024] In the manufacturing method of the thick plate variable cross-section saddle-shaped pipe column, in step 3, the pipe bending process is hot bending or cold bending, which is reasonably selected according to the thickness and curvature of the steel pipe and the company's own equipment; Among them, the hot bending process is as follows: 1) According to the drawing requirements, material specifications, thickness, and radius, make the corresponding horizontal acceptance platform to inspect the levelness and curvature of the finished material; 2) Make the corresponding operating platform according to the material specifications, thickness and radius to ensure that the material is in the horizontal direction during each bending process; 3) Fix the material: put the material into the equipment, clamp it and lay it flat; 4) Fix the mold: fix the radius rail according to the digital requirements of the drawing, and then fix the mold; 5) Adjust the heating equipment: Check whether the heating equipment, water circuits, and circuits are safe and smooth and can operate normally; 6) Hot bending parameters: medium frequency bending machine power 300kw / h, heating temperature 900 degrees ~ 1000 degrees, advancement speed 10mm / min; 7) After the straight pipe is cut, the bending machine is used to put an induction coil on the part of the steel pipe to be bent, and the pipe head is clamped by a mechanical rotating arm. The medium-frequency current is passed through the induction coil to heat the steel pipe. When the temperature of the steel pipe rises to the plastic state, the rear end of the steel pipe is pushed forward by mechanical thrust to bend it. The bent steel pipe part is quickly cooled by coolant. In this way, the steel pipe is continuously bent while being heated, pushed, bent, and cooled; 8) Product testing: test the product’s appearance, angles and geometric dimensions, ovality, curvature and keep self-inspection records; 9) If the curvature deviation of the bent workpiece is outside the deviation range required by the drawing, the workpiece can be put back on the machine tool and the curvature can be corrected using the hydraulic cylinder until the curvature deviation is within the requirements of the drawing; 10) If the ovality deviation of the bent workpiece is found to be outside the deviation range required by the drawing, which affects the docking interface of the workpiece, the workpiece can be put back on the machine tool and the ovality of the pipe mouth can be corrected using a hydraulic cylinder; 11) After forming, the edge of the semicircular tube will be wavy and needs to be reshaped; The cold bending process is as follows: 1) Selection of bending equipment: plane bending of steel pipes is performed by mechanical cold bending, and the equipment is a hydraulic top bending machine; 2) Design of steel pipe bending jig: Before bending the pipe, a special paving die and a pressing die are made according to the cross-sectional size of the steel pipe. The paving die and the pressing die are made of thick plates. The pressing die is welded to the force transmission device of the top press, and the paving die is welded to the fixing device. The opening size of the paving die and the pressing die is determined according to the test data. During operation, the steel pipe is placed on the paving die, and the top press moves the pressing die to hold the steel pipe tightly. Then the top press transmits force to the steel pipe through the transmission device to bend the steel pipe. When the transmission device of the top press is withdrawn, the steel pipe can move freely, which is very convenient for operation, controlling deformation and ensuring quality, and improving work efficiency. 3) Gradual bending of steel pipe: Use hydraulic oil to bend the steel pipe point by point, from the inner arc point to the outer side; the amount of pressure during bending must be strictly controlled so that there is no obvious die mark. The amount of pressure is calculated according to the curvature radius of the steel pipe. It is generally divided into five times of pressure forming to achieve a smooth transition on the surface of the steel pipe without large wrinkles; 4) Bending inspection: After the bending is completed, check the total chord length L of the bent pipe and the arc height H1, H2, H3, H4... of each bending control point to ensure the overall curvature effect of the bent pipe; the error of the total chord length L of the bent pipe is controlled within 10mm, the error of the arc height of each bending control point is controlled within 10mm, and the ovality deviation of the round tube shall not exceed 5mm.

[0025] The manufacturing method of the thick plate variable cross-section saddle-shaped pipe column, in step 4, manufactures an assembly platform and a tire frame, the tire frame is made of HM500×300×11×18 hot-rolled steel, one steel beam is every 1.5m, the tire frame is 6m wide and 9m long, and the upper part is fully covered with t=20mm thick steel plates. The assembled tire frame is laid out and marked, and the isosceles trapezoidal angular part plate (steel column side panel) on one side of the steel column is assembled to the platform and positioned and fixed.

[0026] The method for making the thick plate variable-section saddle-shaped pipe column is as follows: in step 5, the bent steel pipe is first split and cut into corresponding arc-shaped semicircular pipes along the length direction, and then four arc-shaped semicircular pipes are assembled to the platform and fixed by positioning welding. The arc-shaped steel columns on both sides are divided into two sections, and the triangular plates between the lower arc-shaped pipes are evenly divided on the arc-shaped pipes and processed together, avoiding the problem of concentrated welds caused by separate processing and assembly of the triangular plates, and this segmentation can also avoid cross welds.

[0027] The method for making the thick plate variable-section saddle-shaped pipe column is as follows: in step 6, the internal horizontal and vertical partitions are assembled separately, and the welding with the steel pipe is completed. Finally, the top cover plate of the steel column and the upper side panel of the steel column are assembled. The welding personnel enter the internal welding partition through the hole of the internal partition to weld the connection welds between the steel pipe and the side panel of the steel column. When welding the vertical and horizontal internal partitions, the ventilation measures inside the box should be strengthened, and DC fans should be installed at both ends of the component. The main weld of the outside is welded by semi-automatic submerged arc trolley welding. First, lay the component flat, and set a simple trolley track along the arc direction of the upper panel. Pay attention to the control and adjustment of various parameters during welding. After one side is welded, turn over and weld the main weld of the other side.

[0028] The above are only embodiments provided for the present application and are not intended to limit the present application. Although the present application is described in detail with reference to the embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or make equivalent substitutions for some of the technical features therein. However, any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present application should be included in the protection scope of the present application.

Claims

1. A method for manufacturing a thick plate variable cross-section saddle-shaped pipe column, characterized in that: include Step 1: Cutting parts; Step 2: Making the coiled tube; Step 3: semicircular tube forming; Step 4: Setting up the tire frame; Step 5: Assemble and weld the semicircular tubes; Step 6: Assemble and weld the inner partition and remaining parts.

2. The method for manufacturing a thick plate variable cross-section saddle-shaped pipe column according to claim 1, characterized in that: In step 1, the special-shaped rib plate, bottom plate and cover plate are cut by CNC cutting machine; the remaining parts are cut by semi-automatic cutting machine; the allowance in the length direction of the steel pipe is 30mm.

3. The method for manufacturing the thick plate variable cross-section saddle-shaped pipe column according to claim 1, characterized in that: In step 2, a 1,000-ton hydraulic press is used to pre-bend the two ends of the steel plate before rolling the pipe; a CNC plate rolling machine is used to roll the steel pipe.

4. The method for manufacturing a thick plate variable cross-section saddle-shaped pipe column according to claim 1, characterized in that: In step 3, the pipe bending process uses hot bending or cold bending, which is reasonably selected according to the thickness, curvature of the steel pipe and the company's own equipment; Among them, the hot bending process is as follows: 1) According to the drawing requirements, material specifications, thickness, and radius, make the corresponding horizontal acceptance platform to inspect the levelness and curvature of the finished material; 2) Make the corresponding operating platform according to the material specifications, thickness and radius to ensure that the material is in the horizontal direction during each bending process; 3) Fix the material: put the material into the equipment, clamp it and lay it flat; 4) Fix the mold: fix the radius rail according to the digital requirements of the drawing, and then fix the mold; 5) Adjust the heating equipment: Check whether the heating equipment, water circuits, and circuits are safe and smooth and can operate normally; 6) Hot bending parameters: medium frequency bending machine power 300kw / h, heating temperature 900 degrees ~ 1000 degrees, advancement speed 10mm / min; 7) After the straight pipe is cut, the bending machine is used to put an induction coil on the part of the steel pipe to be bent, and the pipe head is clamped by a mechanical rotating arm. The medium-frequency current is passed through the induction coil to heat the steel pipe. When the temperature of the steel pipe rises to the plastic state, the rear end of the steel pipe is pushed forward by mechanical thrust to bend it. The bent steel pipe part is quickly cooled by coolant. In this way, the steel pipe is continuously bent while being heated, pushed, bent, and cooled; 8) Product testing: test the product’s appearance, angles and geometric dimensions, ovality, curvature and keep self-inspection records; 9) If the curvature deviation of the bent workpiece is outside the deviation range required by the drawing, the workpiece can be put back on the machine tool and the curvature can be corrected using the hydraulic cylinder until the curvature deviation is within the requirements of the drawing; 10) If the ovality deviation of the bent workpiece is found to be outside the deviation range required by the drawing, which affects the docking interface of the workpiece, the workpiece can be put back on the machine tool and the ovality of the pipe mouth can be corrected using a hydraulic cylinder; 11) After forming, the edge of the semicircular tube will be wavy and needs to be reshaped; The cold bending process is as follows: 1) Selection of bending equipment: plane bending of steel pipes is performed by mechanical cold bending, and the equipment is a hydraulic top bending machine; 2) Design of steel pipe bending jig: Before bending the pipe, a special paving die and a pressing die are made according to the cross-sectional size of the steel pipe. The paving die and the pressing die are made of thick plates. The pressing die is welded to the force transmission device of the top press, and the paving die is welded to the fixing device. The opening size of the paving die and the pressing die is determined according to the test data. During operation, the steel pipe is placed on the paving die, and the top press moves the pressing die to hold the steel pipe tightly. Then the top press transmits force to the steel pipe through the transmission device to bend the steel pipe. When the transmission device of the top press is withdrawn, the steel pipe can move freely, which is very convenient for operation, controlling deformation and ensuring quality, and improving work efficiency. 3) Gradual bending of steel pipe: Use hydraulic oil to bend the steel pipe point by point, from the inner arc point to the outer side; the amount of pressure during bending must be strictly controlled so that there is no obvious die mark. The amount of pressure is calculated according to the curvature radius of the steel pipe. It is generally divided into five times of pressure forming to achieve a smooth transition on the surface of the steel pipe without large wrinkles; 4) Bending inspection: After the bending is completed, check the total chord length L of the bent pipe and the arc height H1, H2, H3, H4... of each bending control point to ensure the overall curvature effect of the bent pipe; the error of the total chord length L of the bent pipe is controlled within 10mm, the error of the arc height of each bending control point is controlled within 10mm, and the ovality deviation of the round tube shall not exceed 5mm.

5. The method for manufacturing the thick plate variable cross-section saddle-shaped pipe column according to claim 1, characterized in that: In step 5, the bent steel pipe is first split and cut into corresponding arc-shaped semicircular tubes along the length direction, and then the four arc-shaped semicircular tubes are assembled to the platform and fixed by positioning welding. The arc-shaped steel columns on both sides are divided into two sections, and the triangular plates between the lower arc-shaped tubes are evenly divided on the arc-shaped tubes for processing together, avoiding the problem of concentrated welds caused by separate processing and assembly of the triangular plates, and this segmentation can also avoid cross welds.

6. The method for manufacturing the thick plate variable cross-section saddle-shaped pipe column according to claim 1, characterized in that: In step 6, assemble the internal horizontal and vertical partitions respectively, complete the welding with the steel pipe, and finally assemble the top cover plate of the steel column and the upper side panel of the steel column. The welding personnel enter the internal welding partition through the hole of the internal partition to weld the connection welds between the steel pipe and the side panel of the steel column. When welding the vertical and horizontal internal partitions, the ventilation measures inside the box should be strengthened, and DC fans should be installed at both ends of the components. The main weld of the outside is welded by semi-automatic submerged arc trolley. First, lay the component flat, set a simple trolley track along the arc direction of the upper panel, pay attention to the control and adjustment of various parameters during welding, and turn over to weld the main weld of the other side after one side is welded.

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