Flange manufacturing method

Abstract

The invention relates to the technical field of machinery, and discloses a flange manufacturing method which comprises the following specific steps: S1, selecting alloy steel, cutting the alloy steel on a shearing machine, performing secondary cutting on the alloy steel by using a laser cutting machine, performing cold pressing on the alloy steel on a cold pressing machine by using a mold to form a body, and controlling the cold pressing pressure to be 25-35 MPA; and S2, punching is conducted on the formed body through punching equipment, grooving is conducted on one side of the primarily-formed flange through a metal grooving machine after punching is completed, and the depth of a groove is one third of the thickness of the flange. By using the alloy steel and adding carbon, chromium, manganese and silicon into the alloy steel, the flange made of the alloy steel is more corrosion-resistant, the corrosion resistance of the flange can be remarkably improved, the service life of the flange made of the alloy steel can be remarkably prolonged, the maintenance frequency is reduced, and therefore manpower and material resources are saved.

Description

Technical Field

[0001] The invention relates to the field of mechanical technology, in particular to a method for manufacturing a flange. Background Art

[0002] A flange is a connecting piece at the opening of a container. When a compact connection and rigidity are required, a short and thick flange can be used instead of a welded pipe, such as a sight glass, hand hole, and the outlet of a stirring shaft. A flange is also called a flange and is a mechanical component used to connect pipes, containers, or equipment.

[0003] Currently, the existing flange materials will oxidize on the surface when exposed to moisture, chemicals or high temperature environments, and have insufficient corrosion resistance. Regular inspection and maintenance are required to ensure safety and reliability, which not only consumes a lot of manpower and material resources, but also increases maintenance costs. This corrosion will not only reduce the strength and sealing performance of the flange, but also cause structural failure or leakage. Summary of the invention

[0004] In view of the deficiencies of the prior art, the present invention provides a method for manufacturing a flange, which solves the problem of structural failure or leakage caused by insufficient corrosion resistance and poor sealing performance.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: A method for making a flange, comprising the following specific steps:

[0006] Step S1: selecting alloy steel, cutting it on a shearing machine, and then performing secondary cutting on the alloy steel using a laser cutting machine. Using a mold on a cold press machine, the alloy steel is cold pressed into a body, and the cold pressing pressure is controlled at 25-35 MPa;

[0007] Step S2: punching the formed body with a punching device, and then slotting one side of the initially formed flange with a metal slotting machine after the punching is completed, and the depth of the slot is one third of the thickness of the flange;

[0008] Step S3: turning the grooved flange so that the inner diameter of the flange is consistent with the outer diameter of the pipe, using a polishing machine, placing the turned flange into the polishing machine, adding a cleaning agent and mixing it with the polishing particles in the polishing machine, and then adding clean water;

[0009] Step S4: sandblast the inner diameter of the flange polished in step S3 using a sandblasting machine, and sandblast the two side surfaces of the flange and the area adjacent to the inner diameter to clean the dust on the surface of the flange, and weld the flange to the pipe using a welding machine;

[0010] Step S5: Performing dimensional and appearance inspection on the welded flange and performing performance testing.

[0011] Preferably, in step S1, the preparation of the alloy steel comprises the following steps:

[0012] Step S11: preparing the following raw materials by mass percentage: carbon 1.6%-1.8%, chromium 10%-15%, silicon 2%-3.8%, titanium 12%-24%, manganese 16%-18%, aluminum 2%-25%, copper 1%-12%, sulfur 25%-35%, phosphorus 2%-25%, rare earth 12%-24%, lead 1%-10%, tin 1%-10%;

[0013] Step S12: placing the raw materials in a smelting furnace according to a proportion for smelting, and adding a deoxidizer to form molten steel;

[0014] Step S13: Degassing and refining the molten steel in sequence, casting it into a steel billet, heat treating the steel billet, rolling or forging the steel billet, and cooling it for standby use.

[0015] Preferably, in step S5, the size and appearance inspection includes inspecting the outer diameter, inner diameter, thickness and hole size of the welded flange using a vernier caliper or a micrometer, and detecting potential cracks on the flange surface using a crack detector.

[0016] Preferably, in step S5, the performance test includes:

[0017] Pressure test: Use a pressure tester, connect the flange to the pressure tester, apply pressure, and then observe;

[0018] Strength test: Use a tensile testing machine, place the flange on the tensile testing machine, and apply tensile force until the flange is destroyed;

[0019] Corrosion resistance test: Use a salt spray test chamber to place the flange in a salt spray test chamber to simulate the marine environment and observe the degree of flange corrosion;

[0020] Temperature resistance test: Use a high temperature furnace or a low temperature box, place the flange in a high temperature furnace or a low temperature box, and observe the changes in the size, strength and performance of the flange;

[0021] Sealing performance test: Use a leak detector, connect the flange to the pipe, apply pressure, and observe the flange.

[0022] Preferably, the temperature is maintained at 1700° C. for 60 minutes during the smelting process.

[0023] Preferably, the temperature is maintained at 1600° C. for 30 minutes during the smelting process.

[0024] Preferably, when the molten steel is cast into a steel billet, the molten steel at a temperature of 1550° C. is poured into the mold at a uniform speed.

[0025] Preferably, when the molten steel is cast into a steel billet, the molten steel at a temperature of 1650° C. is poured into the mold at a uniform speed.

[0026] Preferably, the degassing treatment uses a vacuum pump, the molten steel is placed in a vacuum container, and the gas in the container is extracted by the vacuum pump to precipitate the gas in the molten steel.

[0027] Preferably, the refining treatment adopts an electroslag remelting refining treatment method, which utilizes electric arc to heat the molten metal and removes gas and inclusions in the molten steel through electromagnetic stirring and gravity sedimentation of the electroslag pool.

[0028] The present invention provides a method for manufacturing a flange, which has the following beneficial effects:

[0029] 1. The present invention uses alloy steel and adds carbon, chromium, manganese and silicon to the alloy steel, so that the flange made of the alloy steel is more corrosion-resistant and can significantly improve its corrosion resistance. The use of alloy steel to manufacture the flange can significantly extend its service life and reduce the maintenance frequency, thereby saving manpower and material resources.

[0030] 2. In order to ensure the firmness and sealing of the connection parts, the present invention adds a unique groove structure to the flange design. A groove of a corresponding shape is opened on one side of each flange, and a sealing ring made of alloy steel is embedded between the opposite grooves of the two flanges when in use, which effectively enhances the strength and sealing of the flange and can effectively avoid leakage problems caused by structural failure. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 A flow chart of a method for manufacturing a flange according to the present invention;

[0032] Figure 2 The present invention is a flow chart of the preparation of alloy steel in a flange manufacturing method. DETAILED DESCRIPTION

[0033] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0034] Embodiment 1:

[0035] Please see attached Figure 1-Figure 2 The embodiment of the present invention provides a method for manufacturing a flange, comprising the following specific steps:

[0036] Step S1: Select alloy steel, cut it on a shearing machine, use a laser cutting machine to perform secondary cutting on the alloy steel, and use a mold to cold press the alloy steel to form a body on a cold press machine, and the cold pressing pressure is controlled at 25 MPa;

[0037] Step S2: punching the formed body with a punching device, and then slotting one side of the initially formed flange with a metal slotting machine after the punching is completed, and the depth of the slot is one third of the thickness of the flange;

[0038] Step S3: turning the initially formed flange so that the outer diameter of the cam is consistent with the outer diameter of the pipe, using a polishing machine, placing the turned flange into the polishing machine, adding a cleaning agent and mixing it with the polishing particles in the polishing machine, and then adding clean water;

[0039] Step S4: sandblast the inner diameter of the flange polished in step S3 using a sandblasting machine, and sandblast the two side surfaces of the flange and the area adjacent to the inner diameter to clean the dust on the surface of the flange, and weld the flange to the pipe using a welding machine;

[0040] Step S5: Finally, the welded flange is inspected for size and appearance and subjected to performance testing.

[0041] In step S1, the preparation of alloy steel includes the following steps:

[0042] Step S11: Prepare the following raw materials by mass percentage: 1.6% carbon, 10% chromium, 2% silicon, 12% titanium, 17% manganese, 2% aluminum, 1.4% copper, 25% sulfur, 10% phosphorus, 12% rare earth, 4% lead, and 3% tin;

[0043] Step S12: putting the raw materials into a smelting furnace according to the proportion for smelting, and adding a deoxidizer at the same time;

[0044] Step S13: The produced molten steel is then degassed, and after further degassing, the molten steel is refined, the degassed and refined molten steel is cast into a steel billet, the steel billet is heat treated, and then the steel billet is rolled or forged, and the rolled or forged steel is cooled for standby use.

[0045] In step S5, the dimension and appearance inspection uses a vernier caliper or a micrometer to inspect the outer diameter, inner diameter, thickness and hole size of the flange, and uses a crack detector to detect potential cracks on the flange surface.

[0046] In step S5, the performance test includes the following specific tests:

[0047] Pressure test: Use a pressure tester, connect the flange to the pressure tester, apply pressure, and then observe;

[0048] Strength test: Use a tensile testing machine, place the flange on the tensile testing machine, and apply tensile force until the flange is destroyed;

[0049] Corrosion resistance test: Use a salt spray test chamber to place the flange in a salt spray test chamber to simulate the marine environment and observe the degree of flange corrosion;

[0050] Temperature resistance test: Use a high temperature furnace or a low temperature box, place the flange in a high temperature furnace or a low temperature box, and observe the changes in the size, strength and performance of the flange;

[0051] Sealing performance test: Use a leak detector, connect the flange to the pipe, apply pressure, and observe the flange.

[0052] The temperature was maintained at 1700°C for 60 minutes during the melting process.

[0053] The temperature was maintained at 1600°C for 30 minutes during the melting process.

[0054] When the molten steel is cast into a steel billet, the molten steel at a temperature of 1550°C is poured into the mold at a uniform speed.

[0055] When molten steel is cast into a steel billet, molten steel at a temperature of 1650°C is poured into the mold at a uniform speed.

[0056] The degassing process utilizes the characteristic of vacuum pumps that can extract air. The molten steel is placed in a vacuum container and the gas in the container is extracted by a vacuum pump to precipitate the gas in the molten steel.

[0057] The refining process adopts the electroslag remelting refining method, which uses electric arc to heat the molten metal and removes gas and inclusions in the molten steel through electromagnetic stirring and gravity sedimentation of the electroslag pool.

[0058] Embodiment 2:

[0059] Please refer to the attached Figure 1-Figure 2 The embodiment of the present invention provides a method for manufacturing a flange, comprising the following specific steps:

[0060] Step S1: selecting alloy steel, cutting it on a shearing machine, and then performing secondary cutting on the alloy steel using a laser cutting machine. Using a mold on a cold press machine, the alloy steel is cold pressed into a body, and the cold pressing pressure is controlled at 35 MPa;

[0061] Step S2: punching the formed body with a punching device, and then slotting one side of the initially formed flange with a metal slotting machine after the punching is completed, and the depth of the slot is one third of the thickness of the flange;

[0062] Step S3: further turning the initially formed flange so that the outer diameter of the cam is consistent with the outer diameter of the pipe, using a polishing machine, placing the turned flange into the polishing machine, adding a cleaning agent and mixing it with the polishing particles in the polishing machine, and then adding clean water;

[0063] Step S4: sandblast the inner diameter of the flange polished in step S3 using a sandblasting machine, and sandblast the two side surfaces of the flange and the area adjacent to the inner diameter to clean the dust on the surface of the flange, and weld the flange to the pipe using a welding machine;

[0064] Step S5: Finally, the welded flange is inspected for size and appearance and subjected to performance testing.

[0065] When machining flanges made of alloy steel, a two-step cutting process is required to ensure that the final size and shape meet the requirements;

[0066] The first step is to use a shearing machine to cut the whole piece of alloy steel, just like using scissors to cut paper, to cut the huge alloy steel plate into smaller sizes. The key to this step is efficiency. The high power and sharp blade of the shearing machine can quickly and accurately cut the required size, laying the foundation for subsequent processing steps;

[0067] The second step is to use a laser cutting machine for secondary cutting to cut the cut alloy steel into the required specific shape. Different from the rough cutting method of the shearing machine, the laser cutting machine uses a high-energy laser beam to accurately cut complex graphics and shapes. Its non-contact cutting feature avoids deformation and damage to the material, ensures the smoothness of the cutting edge, and provides a high-quality surface for subsequent assembly and processing.

[0068] Through the combination of shearing machine and laser cutting machine, alloy steel can be effectively processed into shapes and sizes that meet design requirements, ensuring the accuracy and overall performance of the flange. This double cutting process not only improves processing efficiency, but also ensures processing quality. It is a key link in the manufacture of alloy steel flanges.

[0069] Before welding, the flange is sandblasted not only to increase friction, but also to improve the quality and reliability of the weld;

[0070] The rough surface after sandblasting can increase the friction between the flange and the pipe, making the two in closer contact during welding, effectively preventing gaps or pores from appearing during welding, thereby improving welding quality;

[0071] During welding, the metals need to fuse together after melting. The rough surface after sandblasting can provide a larger contact area, which is conducive to full fusion between the fusion and improve the strength and reliability of the welded joint.

[0072] The surface after sandblasting can form microscopic bumps and depressions. These microstructures can absorb the stress concentration during welding and slow down the stress transfer, thereby improving the fatigue resistance of the welded joint and extending its service life.

[0073] In step S1, the preparation of alloy steel includes the following steps:

[0074] Step S11: Prepare the following raw materials by mass percentage:

[0075] Carbon 1.8%, chromium 12%, silicon 3%, titanium 17%, manganese 18%, aluminum 2%, copper 3%, sulfur 26.2%, phosphorus 2%, rare earth 12%, lead 2%, tin 1%;

[0076] Step S12: putting the raw materials into a smelting furnace according to the proportion for smelting, and adding a deoxidizer at the same time;

[0077] Step S13: The produced molten steel is then degassed, and after further degassing, the molten steel is refined, the degassed and refined molten steel is cast into a steel billet, the steel billet is heat treated, and then the steel billet is rolled or forged, and the rolled or forged steel is cooled for standby use.

[0078] In step S5, the dimension and appearance inspection uses a vernier caliper or a micrometer to inspect the outer diameter, inner diameter, thickness and hole size of the flange, and uses a crack detector to detect potential cracks on the flange surface.

[0079] In step S5, the performance test includes the following specific tests:

[0080] Pressure test: Use a pressure tester, connect the flange to the pressure tester, apply pressure, and then observe;

[0081] Strength test: Use a tensile testing machine, place the flange on the tensile testing machine, and apply tensile force until the flange is destroyed;

[0082] Corrosion resistance test: Use a salt spray test chamber to place the flange in a salt spray test chamber to simulate the marine environment and observe the degree of flange corrosion;

[0083] Temperature resistance test: Use a high temperature furnace or a low temperature box, place the flange in a high temperature furnace or a low temperature box, and observe the changes in the size, strength and performance of the flange;

[0084] Sealing performance test: Use a leak detector, connect the flange to the pipe, apply pressure, and observe the flange.

[0085] The temperature was maintained at 1700°C for 60 minutes during the melting process.

[0086] The temperature was maintained at 1600°C for 30 minutes during the melting process.

[0087] When the molten steel is cast into a steel billet, the molten steel at a temperature of 1550°C is poured into the mold at a uniform speed.

[0088] When molten steel is cast into a steel billet, molten steel at a temperature of 1650°C is poured into the mold at a uniform speed.

[0089] The degassing process utilizes the characteristic of vacuum pumps that can extract air. The molten steel is placed in a vacuum container and the gas in the container is extracted by a vacuum pump to precipitate the gas in the molten steel.

[0090] The refining process adopts the electroslag remelting refining method, which uses electric arc to heat the molten metal and removes gas and inclusions in the molten steel through electromagnetic stirring and gravity sedimentation of the electroslag pool.

[0091] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for manufacturing a flange, characterized in that: The specific steps include: Step S1: selecting alloy steel, cutting it on a shearing machine, and then performing secondary cutting on the alloy steel using a laser cutting machine. Using a mold on a cold press machine, the alloy steel is cold pressed into a body, and the cold pressing pressure is controlled at 25-35 MPa; Step S2: punching the formed body with a punching device, and then slotting one side of the initially formed flange with a metal slotting machine after the punching is completed, and the depth of the slot is one third of the thickness of the flange; Step S3: turning the grooved flange so that the inner diameter of the flange is consistent with the outer diameter of the pipe, using a polishing machine, placing the turned flange into the polishing machine, adding a cleaning agent and mixing it with the polishing particles in the polishing machine, and then adding clean water; Step S4: sandblast the inner diameter of the flange polished in step S3 using a sandblasting machine, and sandblast the two side surfaces of the flange and the area adjacent to the inner diameter to clean the dust on the surface of the flange, and weld the flange to the pipe using a welding machine; Step S5: Performing dimension and appearance inspection on the welded flange and performing performance testing; In step S1, the preparation of alloy steel includes the following steps: Step S11: preparing the following raw materials by mass percentage: carbon 1.6%-1.8%, chromium 10%-15%, silicon 2%-3.8%, titanium 12%-24%, manganese 16%-18%, aluminum 2%-25%, copper 1%-12%, sulfur 25%-35%, phosphorus 2%-25%, rare earth 12%-24%, lead 1%-10%, tin 1%-10%; Step S12: placing the raw materials in a smelting furnace according to a proportion for smelting, and adding a deoxidizer to form molten steel; Step S13: Degassing and refining the molten steel in sequence, casting it into a steel billet, heat treating the steel billet, rolling or forging the steel billet, and cooling it for standby use.

2. The method for manufacturing a flange according to claim 1, characterized in that: In step S5, the size and appearance inspection includes inspecting the outer diameter, inner diameter, thickness and hole size of the welded flange using a vernier caliper or a micrometer, and detecting potential cracks on the flange surface using a crack detector.

3. The method for manufacturing a flange according to claim 1, characterized in that: In step S5, the performance test includes: Pressure test: Use a pressure tester, connect the flange to the pressure tester, apply pressure, and then observe; Strength test: Use a tensile testing machine, place the flange on the tensile testing machine, and apply tensile force until the flange is destroyed; Corrosion resistance test: Use a salt spray test chamber to place the flange in a salt spray test chamber to simulate the marine environment and observe the degree of flange corrosion; Temperature resistance test: Use a high temperature furnace or a low temperature box, place the flange in a high temperature furnace or a low temperature box, and observe the changes in the size, strength and performance of the flange; Sealing performance test: Use a leak detector, connect the flange to the pipe, apply pressure, and observe the flange.

4. The method for manufacturing a flange according to claim 1, characterized in that: The temperature was maintained at 1700° C. for 60 minutes during the smelting process.

5. The method for manufacturing a flange according to claim 1, characterized in that: The temperature was maintained at 1600° C. for 30 minutes during the smelting process.

6. The method for manufacturing a flange according to claim 1, characterized in that: When the molten steel is cast into a steel billet, the molten steel at a temperature of 1550° C. is poured into a mold at a uniform speed.

7. The method for manufacturing a flange according to claim 1, characterized in that: When the molten steel is cast into a steel billet, the molten steel at a temperature of 1650° C. is poured into a mold at a uniform speed.

8. The method for manufacturing a flange according to claim 1, characterized in that: The degassing treatment uses a vacuum pump to place the molten steel in a vacuum container, and the vacuum pump is used to extract the gas in the container to precipitate the gas in the molten steel.

9. The method for manufacturing a flange according to claim 1, characterized in that: The refining treatment adopts an electroslag remelting refining treatment method, which utilizes electric arc to heat the molten metal, and removes gas and inclusions in the molten steel through electromagnetic stirring and gravity sedimentation of the electroslag pool.

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