T-shaped rib butt joint automatic root-avoiding welding process design method

Abstract

This invention discloses a design method for an automatic, root-cleaning-free welding process for T-rib butt joints. The T-rib includes a face plate and a web plate connected to the face plate. An X-shaped bevel is formed between the face plates and the web plates of adjacent T-ribs. The depth of the inner bevel of the face plate is P = 0.5 × t1 × tg(γ / 2) ÷ tg(β / 2), where t1 is the thickness of the web plate, γ is the angle of the web bevel, and β is the angle of the inner bevel of the face plate. This application provides root-cleaning-free bevel design parameters. The rib end butt joint bevel processing according to these parameters is suitable for automatic welding processes, providing a foundation for high-quality automatic welding of T-rib butt joints, achieving root-cleaning-free results, and creating favorable bevel conditions for automatic gas-shielded welding.

Description

Technical Field

[0001] This invention relates to the field of automatic welding technology, and in particular to a design method for an automatic root-cleaning-free welding process for T-shaped rib butt joints. Background Technology

[0002] Regarding the automatic welding of butt welds in T-shaped ring rib structures, the closest existing technologies are manual shielded metal arc welding and manual semi-automatic gas shielded welding for the longitudinal seams of ring structure splices. Both of these methods involve manually operating the welding torch to complete the welding work, and the welding process is greatly affected by the stability of the welder's operation, requiring high technical skills from the welder.

[0003] The process parameters and requirements of manual shielded metal arc welding and manual semi-automatic gas shielded welding can no longer meet the requirements of automatic welding. Regarding the automatic welding process for butt welds of T-ribs, the automatic welding of butt welds at the ends of high-quality steel T-ribs requires root cleaning, which necessitates improvement. Summary of the Invention

[0004] This application provides a method for designing an automatic, root-cleaning-free welding process for T-rib butt joints, which solves the technical problem that requires root cleaning operations for automatic welding of T-rib butt joints in the prior art.

[0005] This application provides a design method for an automatic root-cleaning-free welding process for T-shaped rib butt joints. The T-shaped rib includes a face plate and a web plate connected to the face plate. An X-shaped bevel is formed between the face plates and the web plates of two adjacent T-shaped ribs. The depth of the inner bevel of the face plate is P = 0.5 × t1 × tg(γ / 2) ÷ tg(β / 2), where t1 is the thickness of the web plate, γ is the angle of the bevel of the web plate, and β is the angle of the inner bevel of the face plate.

[0006] In some embodiments, the angle of the outer bevel of the panel is not less than 55°, and the radius r of the root blunt edge of the panel and the web is not greater than 1 mm.

[0007] In some implementations, when welding two adjacent T-ribs, the assembly gap between the two adjacent T-ribs is controlled to be 3mm-7mm.

[0008] In some implementations, the thickness t of the panel is controlled between 34mm and 50mm, and the thickness t1 of the web is controlled between 14mm and 30mm.

[0009] In some implementations, a test plate simulating a T-rib is used for welding verification to obtain the welding shrinkage dimensions of T-ribs of different specifications. The welding shrinkage dimensions are used to clarify the layout dimensions required for manufacturing T-ribs without allowance.

[0010] In some implementations, when the panel thickness t is 34mm≤t≤40mm, the depth of the inner bevel of the panel is controlled at 1 / 2t1±2mm.

[0011] When the panel thickness t is 40mm < t ≤ 50mm, the depth of the inner bevel of the panel is 18mm.

[0012] In some embodiments, the opening size of the bevel of the web is equal to the opening size of the inner bevel of the face plate.

[0013] In some embodiments, the bevel angle of the web is greater than the bevel angle of the inner side of the panel. At the corner from the web to the panel, the bevel angle at the corner gradually changes and smoothly transitions from the bevel angle of the web to the inner side of the panel.

[0014] In some embodiments, the T-ribs are machined with the aforementioned bevels, and TIG root pass welding and MIG fill pass welding are performed on the X-shaped bevels to form a spindle-shaped weld at the corner from the web to the face plate.

[0015] In some implementations, the welding sequence for two adjacent T-ribs includes:

[0016] One side of the web and the inside of the panel are integrally welded;

[0017] Perform vertical welding on the outer side of the panel;

[0018] The T-shaped ribs are turned over, and then the other side of the web plate and the inner side of the panel are welded together.

[0019] The beneficial effects of this application are as follows: It provides an automatic, root-cleaning-free welding process design method for T-shaped rib butt joints, mainly used for the automatic welding of T-shaped ring rib structures. The T-shaped ring rib structure includes multiple T-shaped ribs distributed sequentially along the circumferential direction. Adjacent T-shaped ribs need to be welded using automatic welding. Each T-shaped rib includes a face plate and a web plate connected to the face plate. The face plate and web plate of adjacent T-shaped ribs need to be butt-jointed. This design method involves designing the butt joint bevel between the face plate and web plate of adjacent T-shaped ribs using an X-shaped bevel scheme, forming an X-shaped bevel between the face plates of adjacent T-shaped ribs. The X-shaped bevel is formed between the webs of two adjacent T-ribs, limiting the depth of the inner bevel of the panel to P = 0.5 × t1 × tg(γ / 2) ÷ tg(β / 2), where t1 is the thickness of the web, γ is the angle of the web bevel, and β is the angle of the inner bevel of the panel. This application provides bevel design parameters for root-cleaning-free welding. The rib end butt bevel processing is performed according to the parameters of this application, which is suitable for automatic welding processes. It provides the basic conditions for high-quality automatic welding of T-rib butt welds, and can achieve the effect of root-cleaning-free welding, creating good bevel conditions for automatic gas shielded welding. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention.

[0021] Figure 1 A schematic diagram showing the X-shaped bevel formed by two adjacent T-ribs in an automatic root-cleaning-free welding process design method for T-rib butt joint provided in this application;

[0022] Figure 2 This is a schematic diagram of the blunt edge at the base of a T-shaped rib.

[0023] Figure 3 A detailed schematic diagram of the X-shaped bevel of the web;

[0024] Figure 4 This is a schematic diagram of the weld seams on the panel;

[0025] Figure 5 This is a schematic diagram of the weld seam of the web plate;

[0026] Figure 6 A schematic diagram illustrating the welding sequence provided in this application.

[0027] Attached diagram labels: 10-panel, 11-inner side, 12-outer side, 20-web, 30-X-shaped bevel. Detailed Implementation

[0028] Regarding the manual shielded metal arc welding (SMAW) and semi-automatic gas shielded welding (GSAW) methods for longitudinal seams in ring-shaped structures, both methods involve manually operating the welding torch, and the welding process is significantly affected by the welder's operational stability. For large-scale, long weld seam welding, a large number of highly skilled welders are required.

[0029] The high-quality ring structure with fully welded longitudinal seams requires ultrasonic testing (Level I) and radiographic testing (Level II) to pass after welding. The welding quality requirements are high, and the use of automatic welding is beneficial to ensure welding quality, improve welding efficiency, and reduce the welder's strength.

[0030] Automatic welding has advantages such as controllable welding speed, continuous and stable welding process, and no impact from the welder's physical strength. However, its self-adjustment is worse than that of manual welding, and the stability of the welding process is easily affected by external factors such as the bevel.

[0031] The process parameters and requirements of manual shielded metal arc welding and manual semi-automatic gas shielded welding can no longer meet the requirements of automatic welding. In order to maximize welding efficiency and ensure welding quality, welding speed, welding voltage and current, process requirements and other aspects need to be optimized.

[0032] This application mainly addresses the design problem of root-cleaning-free bevel for automatic welding of T-rib butt welds, and provides root-cleaning-free "spindle-shaped" bevel design parameters. By processing the butt bevel of the rib ends according to the parameters of this patent, the high-quality automatic welding process requirements of T-rib butt welds can be met.

[0033] This application pertains to the automatic welding of T-shaped ring rib structures. The T-shaped ring rib structure comprises multiple T-shaped ribs distributed sequentially along the circumferential direction, requiring the automatic welding of adjacent T-shaped ribs. Please refer to the references. Figure 1 and Figure 2 The T-rib includes a face plate 10 and a web plate 20 connected to the face plate 10. It is necessary to butt-weld the face plates 10 and web plates 20 of two adjacent T-ribs respectively. In the automatic root-cleaning-free welding process design method for T-rib butt welding provided in this application, please refer to... Figure 1 and Figure 3 An X-shaped bevel 30 is formed between the facets 10 and the web 20 of two adjacent T-shaped ribs. The side of the facet 10 facing the web 20 is defined as the inner side 11 of the facet 10, and the side of the facet 10 facing away from the web 20 is defined as the outer side 12 of the facet 10. Figure 1 The image shows the depth P of the inner bevel of panel 10. In this application, the depth P of the inner bevel of panel 10 is P = 0.5 × t1 × tg(γ / 2) ÷ tg(β / 2), where tg is the tangent function in mathematics, × represents multiplication, and ÷ represents division. Figure 3 The display shows t1, where t1 is the thickness of the web plate (20 mm). Figure 3 The diagram shows γ, where γ is the angle of the bevel of the web 20. Figure 1 The display shows β, where β is the angle of the inner bevel of panel 10.

[0034] This application provides design parameters for the root-cleaning-free beveling. The rib end butt beveling is processed according to the parameters of this application, which is suitable for automatic welding process. It provides the basic conditions for high-quality automatic welding process of T-rib butt welds, and can achieve the effect of root-cleaning-free welding, creating good beveling conditions for automatic gas shielded welding.

[0035] This application addresses the automatic gas-shielded welding of T-rib butt welds with a web thickness t1 of 14mm-30mm. It details the dimensional aspects of automatic gas-shielded welding without root cleaning, including the bevel angles, dimensions, and opening widths in various areas and at multiple stations. This ensures weld continuity and bevel processing feasibility during automatic welding without root cleaning. It is a bevel processing method for ring rib structures without allowance, creating favorable bevel conditions, installation accuracy, and deformation control measures for automatic gas-shielded welding.

[0036] The T-rib end bevel design is based on general gas shielded welding bevel dimensions or relevant specialized standards. There are significant differences in thickness and bevel type between the web plate 20 and the face plate 10. Additionally, the opening size at the corner weld transitioning between the web plate 20 and the face plate 10 differs. For example, the bevels for the 14mm-30mm thick web plate 20 and the 34mm-50mm thick face plate 10 are as follows: Figure 1 and Figure 3 As shown, under the condition that the depth P of the inner bevel of the panel 10 is 0.5 × t1 × tg(γ / 2) ÷ tg(β / 2), Figure 1 The angle α of the outer bevel of panel 10 is shown in the diagram, and α is required to be no less than 55°. Figure 2 The image shows the blunt edge at the root of the T-rib; the blunt edge in the welding bevel design is the end face without a bevel. Figure 2 The radius r of the root blunt edge of the panel 10 and the web 20 is shown, and r must not exceed 1 mm.

[0037] Please refer to Figure 1 Adjacent T-ribs are symmetrical with web 20 and face plate 10. After welding, the weld at the corner between web 20 and face plate 10 is spindle-shaped. After the bevel surfaces of the T-ribs are machined, assembly is required. Figure 1 and Figure 3 All of them showed the assembly gap c, which is required to be controlled between 3mm and 7mm.

[0038] Verification was conducted using robotic automated welding of the butt weld bevel of the T-rib. This verification required a test plate that simulated the T-rib, identical in shape and size. By measuring and defining the welding shrinkage of different T-rib specifications, the dimensional requirements for the subsequent zero-margin manufacturing of the entire ring-shaped T-rib were determined. In some implementations, the shrinkage rate of the quarter-rib manufacturing needs to be considered before fabricating the entire ring.

[0039] The web plate 20 and the face plate 10 are integrated into a multi-station process, and consistent bevel width is a crucial parameter for achieving automated welding. The web plate 20 maintains a symmetrical bevel. To maintain consistent bevel width between the inner side 11 of the face plate and the web plate 20, the bevel angles of the face plate 10 and the web plate 20 differ. To ensure the quality of the butt weld of the thicker face plate 10, and the weld quality of the fillet weld between the web plate 20 and the face plate 10, a "spindle shape" is formed in this area to achieve a smooth transition. When using automatic welding, if the bevel width is too small, interference between the welding torch nozzle and the base material will lead to excessive wire extension during root weld welding, affecting the stability of the welding arc. If the bevel width is too large, it will result in increased filler volume and an excessively large capping layer. To solve this problem, the bevel width of the first welded surface is based on the face plate 10 during bevel design, while also reducing the unevenness of filler filling between the inner and outer welds of the face plate 10. The bevel width of the first welded surface refers to... Figure 4 The size b2 and Figure 5 In the design, b1 refers to the bevel width, which is also the opening size. b1 refers to the opening size of the bevel of the web 20, and b2 refers to the opening size of the inner bevel of the panel 10. b2 must equal b1, meaning the opening size of the bevel of the web 20 must be equal to the opening size of the inner bevel of the panel 10. In actual design, the opening size b1 is kept above 20mm.

[0040] The bevel depth is a crucial welding parameter and a key factor in ensuring the consistency of the weld formation coefficient. To guarantee the welding quality and weld appearance consistency of the root and filler zones, in the root-cleaning bevel design, the panel 10 is cut with an X-shaped bevel 30. When the thickness t of the panel 10 is 34mm ≤ t ≤ 40mm, the depth of the inner bevel of the panel 10 is 1 / 2 the thickness t1 of the web 20, with an allowable deviation of 0–2mm. When the thickness t of the panel 10 is 40mm < t ≤ 50mm, the depth of the inner bevel of the panel 10 is 18mm. The bevels and filler amounts on both sides of the panel 10 are appropriately asymmetrical. Figure 4 The graphic clearly represents the meaning of asymmetry.

[0041] The bevel design details at the corner of the weld between the T-rib web 20 and the panel 10 are one of the key factors ensuring the qualified automatic welding during the transition between horizontal and vertical work positions. The "spindle-shaped" bevel design at the corner achieves a smooth transition from 80° to 60°, where 80° is the bevel angle of the web 20 and 60° is the inner bevel angle of the panel 10. It should be noted that the bevel angle of the web 20 is not limited to 80°, and the inner bevel angle of the panel 10 is not limited to 60°, but the bevel angle of the web 20 is greater than the inner bevel angle of the panel 10. At the corner between the web 20 and the panel 10, the bevel angle at the corner gradually transitions from the bevel angle of the web 20 to the inner bevel angle of the panel 10. A smooth transition is required; it is also necessary to ensure that the opening size of the bevel of the web plate 20 is equal to the opening size of the inner bevel of the panel 10. The bevel depth of the web plate 20 is 1 / 2 of the thickness of the web plate 20. The bevel depth of the inner side 11 of the panel is close to 1 / 2 of the thickness of the panel 10. The bevel depth of the inner side 11 of the panel is less than 1 / 2 of the thickness of the panel 10. The bevel depth from the web plate 20 to the panel 10 is a change of about 1 / 2 of the thickness of the web plate 20 - 1 / 2 of the thickness of the web plate 20 + the weld thickness - 1 / 2 of the side plate thickness of the panel 10. Finally, the bevel angle and depth gradually change to achieve the change of the final weld filler amount.

[0042] This patented technology enables automatic welding of butt welds with unequal thicknesses made of high-strength, high-quality steel T-ribs without root cleaning, ensuring consistent bevels and uniform assembly precision, and meeting the requirements of multi-station integrated automatic welding processes. It solves the problem of root-cleaning bevel design for automatic welding of butt welds on the ends of high-quality steel T-ribs with web thicknesses of 16-28mm and face plates of 1032-46mm alloy, providing root-cleaning "spindle-shaped" bevel design parameters. Beveling the T-rib ends according to these parameters can meet the high-quality automatic welding process requirements for various T-rib butt welds.

[0043] The aforementioned automatic root-cleaning-free welding process design method for T-rib butt joints has been applied in robotic automatic gas-shielded welding of butt joints between the web 20 and face plate 10 ends of T-shaped annular ribs with diameters of 4m-10m. Based on the above design method, this application also studies the welding method, machining the aforementioned bevel into the T-rib, and performing TIG root pass welding and MIG fill pass welding at the X-shaped bevel 30. Figure 4 and Figure 5 Both demonstrate the weld seams of the root pass and fill pass, and can form a spindle-shaped weld seam at the corner from the web 20 to the face plate 10. TIG stands for Tungsten Inert Gas Welding, also known as non-consumable electrode inert gas shielded arc welding; MIG stands for Metal Inert Gas Arc Welding. MIG welding is inert gas shielded arc welding. These two welding technologies have been widely used in professional fields and will not be elaborated further here.

[0044] Please refer to Figure 6 , Figure 6 A welding sequence is shown in which the face plates 10 are arranged in an upright position and the web plates 20 are arranged in a horizontal position. Figure 6 In the diagram, ①②③ expresses both the welding direction and the welding sequence. ① indicates that the web 20 and the inner side 11 of the panel are welded together. ② indicates that the outer side 12 of the panel is welded in a vertical position. ③ indicates that the other side of the web 20 and the inner side 11 of the panel are welded together.

[0045] The following will specifically describe the robotic automated gas shielded welding of the butt weld between the web plate 20 and the face plate 10 of a T-shaped annular rib with a diameter of 4m-10m. The main process is as follows: 1) Select T-shaped ribs with a web plate thickness of 22mm and a face plate thickness of 44mm, and bevel type according to... Figure 1 and Figure 3 Processing; 2) According to Figure 6 Weld code ① in the figure indicates that the web 20 and the panel 10 are integrally welded, according to Figure 6② Perform upright welding on the outer side 12 of panel 10 according to the weld code ②; 3) Then turn the T-rib over and follow the Figure 6 Weld code ③ is used to perform integrated welding on the other side of the web 20 and the inner side 11 of the panel. Here, "one side of the web 20" and "the other side of the web 20" refer to the two sides in the thickness direction of the web 20. 4) After welding, non-destructive testing and mechanical property tests are performed in accordance with relevant standards. The test results consistently meet the relevant standards.

[0046] It should be noted that the welding paths for both TIG root pass and MIG fill pass are as follows: Figure 6 The welding sequence is shown in ①②③.

[0047] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the invention.

[0048] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A method for designing an automatic, root-cleaning-free welding process for T-shaped rib butt joints, characterized in that, The T-shaped rib includes a face plate and a web plate connected to the face plate. An X-shaped bevel is formed between the face plates and between the web plates of two adjacent T-shaped ribs. The depth of the inner bevel of the face plate is P = 0.5 × t1 × tg(γ / 2) ÷ tg(β / 2), where t1 is the thickness of the web plate, γ is the angle of the bevel of the web plate, and β is the angle of the inner bevel of the face plate. The opening size of the bevel of the web plate is equal to the opening size of the inner bevel of the panel plate and is maintained at more than 20mm. Under the condition that the thickness t of the panel is 34mm≤t≤40mm, the depth of the inner bevel of the panel is controlled at 1 / 2t1±2mm. When the thickness t of the panel is 40mm < t ≤ 50mm, the depth of the inner bevel of the panel is 18mm. The bevel angle of the web is greater than the bevel angle of the inner side of the panel. At the corner between the web and the panel, the bevel angle at the corner gradually changes and smoothly transitions from the bevel angle of the web to the inner side of the panel. The bevel depth of the web is 1 / 2 of the web thickness, the inner bevel depth of the panel is close to 1 / 2 of the panel thickness, and the inner bevel depth of the panel is less than 1 / 2 of the panel thickness.

2. The design method as described in claim 1, characterized in that, The angle of the outer bevel of the panel is not less than 55°, and the radius r of the root blunt edge of the panel and the web is not greater than 1mm.

3. The design method as described in claim 2, characterized in that, When welding two adjacent T-ribs, the assembly gap between the two adjacent T-ribs is controlled between 3mm and 7mm.

4. The design method as described in claim 3, characterized in that, The thickness t of the panel is controlled between 34mm and 50mm, and the thickness t1 of the web is controlled between 14mm and 30mm.

5. The design method as described in claim 1, characterized in that, Welding verification was performed using a test plate simulating the T-rib to obtain the welding shrinkage dimensions of the T-ribs of different specifications. The welding shrinkage dimensions were used to clarify the no-margin manufacturing layout dimensions of the T-ribs.

6. The design method as described in claim 1, characterized in that, TIG root pass welding and MIG fill pass welding are performed at the X-shaped bevel to form a spindle-shaped weld at the corner from the web to the panel.

7. The design method as described in claim 6, characterized in that, The welding sequence for two adjacent T-ribs includes: One side of the web plate and the inner side of the panel are integrally welded; The outer side of the panel is welded in an upright position; The T-shaped ribs are turned over, and then the other side of the abdominal plate and the inner side of the panel are integrally welded.

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