Process for manufacturing a hexagonal flow channel pipe

Abstract

This invention discloses a manufacturing process for a hexagonal flow channel pipe fitting, comprising the following steps: A1: Fabricating two symmetrical semi-circular solid parts, which, when joined together, form a circular part; A2: Creating grooves on the opposing surfaces of the two solid parts, the grooves extending along the length of the solid parts, forming a hexagonal flow channel in the middle when the two solid parts are joined; A3: Creating inclined surfaces on the opposing surfaces of the two solid parts, located on both sides of the grooves, forming a weld seam area between the two opposing inclined surfaces when the two solid parts are joined; A4: Welding and fixing the two solid parts within the weld seam area to obtain the hexagonal flow channel pipe fitting; A5: Welding flanges to the ends of the hexagonal flow channel pipe fitting. This invention can fabricate precisely dimensional hexagonal flow channels inside the pipe fitting, with a simple and reliable process, and the produced pipe fitting meets quality requirements.

Description

Technical Field

[0001] This invention relates to the field of pipe fitting manufacturing technology, specifically to a manufacturing process for a hexagonal flow channel pipe fitting. Background Technology

[0002] The cross-section of the flow channel inside a pipe fitting is generally circular, which can be achieved by drilling. However, in some special cases, the flow channel inside the pipe fitting needs to be hexagonal. However, the current manufacturing process cannot directly produce hexagonal flow channels with a drill bit, and some equipment cannot produce hexagonal flow channels with the required dimensions. Therefore, there is an urgent need for a manufacturing process for hexagonal pipe fittings. Summary of the Invention

[0003] The purpose of this invention is to provide a manufacturing process for hexagonal flow channel pipe fittings, which can create precisely dimensional hexagonal flow channels inside the pipe fittings. The process is simple and reliable, and the quality of the manufactured pipe fittings meets the requirements.

[0004] To solve the above-mentioned technical problems, the present invention adopts the following solution:

[0005] A manufacturing process for a hexagonal flow channel pipe fitting includes the following steps:

[0006] A1: Make two symmetrical semi-circular solid parts, and the two solid parts can be joined together to form a circular part;

[0007] A2: Grooves are made on the opposite surfaces of the two solid parts. The grooves run through the solid parts along their length. When the two solid parts are closed, a hexagonal flow channel is formed in the middle.

[0008] A3: The opposing surfaces of the two solid parts are made into inclined surfaces, which are located on both sides of the groove. After the two solid parts are closed, the two opposing inclined surfaces form a weld area.

[0009] A4: Weld two solid parts to fix them in the weld area to obtain a hexagonal flow channel pipe fitting;

[0010] A5: Hexagonal flow channel pipe fitting end welding flange.

[0011] In this method, two symmetrical semi-circular solid parts are first fabricated, with their opposing surfaces being flat. Next, grooves of appropriate precision are cut along the length of each solid part on these flat surfaces. After the two solid parts are joined, the two opposing grooves form a hexagonal flow channel with composite precision. After the grooves are cut, the surfaces on both sides of the grooves remain flat. These flat surfaces are then machined into inclined surfaces, so that when the two solid parts are joined, the two opposing inclined surfaces form a weld seam area. Welding equipment is then used to weld the two solid parts together within this area, thus fixing them together to obtain a hexagonal flow channel pipe fitting. After the two solid parts are fixed, flanges are welded to one or both ends of the pipe fitting for later connection to corresponding pipelines. This process yields a precisely sized hexagonal flow channel pipe fitting. The process is simple, reliable, and produces pipe fittings that meet quality requirements.

[0012] Optionally, during the process of making the inclined surface, a locking block is formed on the bottom surface of the upper solid part, with the locking block located on both sides of the groove. A slot is formed on the top surface of the lower solid part to match the locking block, with the slot located on both sides of the groove. After the two solid parts are closed, the locking block is inserted into the slot.

[0013] Optionally, the cross-section of the weld area is triangular, with an acute angle between the two inclined surfaces.

[0014] Optionally, before welding the two solid parts, a suitable support needs to be placed in the hexagonal flow channel, and the length of the support is greater than the length of the solid parts.

[0015] Optionally, the support member is a hexagonal cube with a hexagonal cross-section.

[0016] Optionally, before welding, one of the solid parts is placed on the welding table, and then the support is placed in the groove of the solid part with both ends of the support located on the outside of the solid part. Then, the other solid part is fastened onto the solid part below, and the two solid parts and the support are locked and fixed along the length of the welding table using multiple clamps.

[0017] Optionally, when welding the flange, the flange has a hexagonal hole in the middle that matches the support member. The end of the support member passes through the hexagonal hole in the middle of the flange, and welding begins after the inner side of the flange contacts the end face of the pipe fitting.

[0018] Optionally, when welding two solid parts, a symmetrical welding method can be used, with each layer added progressively.

[0019] Optionally, after the flange welding is completed, the entire pipe fitting undergoes stress-relieving heat treatment.

[0020] Optionally, after heat treatment, the pipe is cooled, and after cooling, the support is destroyed using a deep hole boring machine, the support is removed, and finally the pipe is polished.

[0021] The beneficial effects of this invention are as follows:

[0022] 1. In this invention, hexagonal flow channel fittings with precise dimensions can be obtained by processing hexagonal flow channels in segments. This process is simple and reliable, and the quality of the fittings produced meets the requirements.

[0023] 2. Before welding the two solid parts, a support component adapted to the size of the hexagonal flow channel is set between the two grooves. After fixing the two solid parts, the support component can slide along the length of the hexagonal flow channel. By sliding the support component, the straightness of the hexagonal flow channel can be checked. If there is no jamming during the sliding process, the straightness of the hexagonal flow channel is considered to be qualified. At the same time, during welding, the support component applies an external force to the inner side of the flow channel weld, which can reduce the shrinkage of the weld during the welding process.

[0024] 3. When splicing two solid parts, a socketing method with inserting a card block into a slot is used to avoid misalignment during the welding process and ensure that the dimensions of the hexagonal flow channel meet the requirements. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the process flow of the present invention;

[0026] Figure 2 This is a structural schematic diagram of a semi-circular solid component;

[0027] Figure 3 A schematic diagram of the structure after machining a groove into a semi-circular solid part;

[0028] Figure 4 Structural drawing for machining a solid part with locking blocks;

[0029] Figure 5 Structural drawing for machining a solid part with a slot;

[0030] Figure 6 This is a schematic diagram of the cross-sectional structure of the card block before it is inserted into the card slot;

[0031] Figure 7 This is a schematic diagram of the cross-sectional structure after the card block is inserted into the card slot;

[0032] Figure 8 This is a diagram showing the end structure of a solid component locked onto a welding table.

[0033] Figure 9 This is a diagram showing the distribution structure of the clamps;

[0034] Figure 10 This is a structural diagram showing the assembly of the flange and its support components.

[0035] Figure 11 This is a cross-sectional view of the support component.

[0036] Reference numerals: 1-Solid part, 2-Groove, 3-Straight surface, 4-Clamping block, 5-Clamping groove, 6-Inclined surface, 7-Welding area, 8-Hexagonal flow channel, 9-Welding table, 10-Clamping clamp, 11-Flange, 12-Support, 13-Through hole, 14-Through groove. Detailed Implementation

[0037] The present invention will be further described in detail below with reference to the embodiments and accompanying drawings, but the embodiments of the present invention are not limited thereto.

[0038] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "longitudinal," "lateral," "horizontal," "inner," "outer," "front," "rear," "top," and "bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this invention is in use. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0039] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set up," "have," "install," "connect," and "connect" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0040] Example

[0041] like Figure 1 As shown, the manufacturing process of a hexagonal flow channel pipe fitting includes the following steps:

[0042] A1: Make two symmetrical semi-circular solid parts 1. The two solid parts 1 are joined together to form a circular part.

[0043] A2: Grooves 2 are opened on the opposite surfaces of the two solid parts 1. The grooves 2 penetrate the solid parts 1 along the length of the solid parts 1. After the two solid parts 1 are closed, a hexagonal flow channel 8 is formed in the middle.

[0044] A3: The opposing surfaces of the two solid parts 1 are made into inclined surfaces 6. The inclined surfaces 6 are located on both sides of the groove 2. After the two solid parts 1 are closed, the two inclined surfaces 6 that are opposite each other form a weld area 7.

[0045] A4: Weld two solid parts 1 in the weld area 7 to obtain a hexagonal flow channel 8 fitting;

[0046] A5: Hexagonal flow channel 8 pipe fitting end welding flange 11.

[0047] In this embodiment, the solid length of the semicircle is generally 2000mm, such as... Figure 2 As shown, first make two symmetrical semi-circular solid parts 1. The opposite surfaces of the two solid parts 1 are flat surfaces 3, as shown. Figure 3 As shown, a groove 2 of the required precision is then formed on the flat surface 3 along the length of the solid part 1. After the two solid parts 1 are closed, the two opposing grooves 2 form a hexagonal flow channel 8 with a composite precision. After the groove 2 is formed, the surfaces on both sides of the groove 2 are still flat surfaces 3, as shown. Figure 4 and Figure 5 As shown, when the flat surface 3 is machined into an inclined surface 6, so that the two solid parts 1 are joined together, as shown... Figure 7 As shown, the weld area 7 is formed between two opposite inclined surfaces 6. Welding is then carried out in the weld area 7 using welding equipment to fix the two solid parts 1 to obtain a hexagonal flow channel 8 pipe fitting. After the two solid parts 1 are fixed by welding, flanges 11 are welded to one or both ends of the pipe fitting. The flanges 11 are used to connect to the corresponding pipelines later. This process can produce a hexagonal flow channel 8 pipe fitting with accurate dimensions. The process is simple and reliable, and the quality of the pipe fittings produced meets the requirements.

[0048] Furthermore, such as Figure 6 As shown, during the process of making the inclined surface 6, a locking block 4 is formed on the bottom surface of the upper solid part 1. The locking block 4 is located on both sides of the groove 2. A slot 5 that matches the locking block 4 is formed on the top surface of the lower solid part 1. The slot 5 is located on both sides of the groove 2. After the two solid parts 1 are closed, the locking block 4 is inserted into the slot 5.

[0049] Specifically, when splicing the two solid parts 1, the insertion of the card block 4 into the card slot 5 is adopted to avoid misalignment during the welding process of the two solid parts 1, and to ensure that the dimensions of the hexagonal flow channel 8 meet the requirements.

[0050] Furthermore, the cross-section of the weld region 7 is triangular, and the included angle between the two inclined surfaces 6 is an acute angle.

[0051] Specifically, the angle between the two opposing inclined surfaces 6 is 60°, and a triangular weld area 7 is adopted. During the welding process, the weld area 7 is completely filled with solder to form a triangular connection. The triangle has higher stability, which makes the welding of the two solid parts 1 stronger.

[0052] Furthermore, before welding the two solid parts 1, a suitable support 12 needs to be placed in the hexagonal flow channel 8, and the length of the support 12 is greater than the length of the solid part 1.

[0053] Furthermore, the support member 12 is a hexagonal cube with a hexagonal cross-section.

[0054] Furthermore, before welding, one of the solid parts 1 is placed on the welding table 9, and then the support 12 is placed in the groove 2 of the solid part 1 with both ends of the support 12 located on the outside of the solid part 1. Then, the other solid part 1 is fastened to the lower solid part 1, and the two solid parts 1 and the support 12 are locked and fixed along the length of the welding table 9 by multiple clamps 10.

[0055] Specifically, such as Figure 8 and Figure 9 As shown, before welding the two solid parts 1, a support 12 adapted to the size of the hexagonal flow channel 8 is set between the two grooves 2. After fixing the two solid parts 1, the support 12 can slide along the length of the hexagonal flow channel 8. By sliding the support 12, the straightness of the hexagonal flow channel 8 can be checked. If no jamming occurs during the sliding process, the straightness of the hexagonal flow channel 8 is considered to be qualified. At the same time, during welding, the support 12 applies an external force to the inner side of the weld seam of the flow channel, which can reduce the shrinkage of the weld seam during the welding process. Figure 11 As shown, a through hole 13 is provided in the center of the hexagonal body to facilitate the subsequent deep hole boring process to break down the hexagonal body and thus better remove the support 12. The hexagonal body is made of copper and has a surface roughness of 1.6. This reduces frictional resistance when sliding to check the straightness of the hexagonal flow channel 8. At the same time, all six vertices of the hexagonal body are chamfered with a chamfer radius of 120°. This ensures that there is a certain gap between the vertices of the hexagonal body and the six corners inside the hexagonal flow channel 8 when the hexagonal body slides in the hexagonal flow channel 8, reducing the contact area and making the sliding of the hexagonal body smoother. Furthermore, through slots 14 can be opened on the six surfaces of the hexagonal body to save material.

[0056] Furthermore, such as Figure 10 As shown, when welding flange 11, flange 11 has a hexagonal hole in the middle that is adapted to support member 12. The end of support member 12 passes through the hexagonal hole in the middle of flange 11. Welding begins after the inner side of flange 11 contacts the end face of pipe fitting.

[0057] Furthermore, when welding the two solid parts 1, a symmetrical welding method is adopted, with each layer added progressively.

[0058] Furthermore, after flange 11 is welded, the entire pipe fitting undergoes stress-relieving heat treatment.

[0059] Furthermore, after the heat treatment is completed, the pipe is cooled. After cooling, the support 12 is broken using a deep hole boring machine and removed. Finally, the pipe is polished.

[0060] The specific principle of this process is as follows: First, the raw material for manufacturing solid part 1 is S31068. The raw material is forged to obtain a semi-circular solid part 1. The flat surface 3 of solid part 1 is rough milled, heat treated, and finish milled to obtain a semi-hexagonal groove 2. Then, the dimensions of groove 2 are checked by measuring tools to ensure that they meet the standards. The surface roughness of groove 2 is better than 3.2. At the same time, a locking block 4 is milled on the bottom surface of the upper solid part 1. The locking block 4 is located at both ends of the side wall of the upper groove 2 and protrudes downward. A locking groove 5 that matches the locking block 4 is milled on the top surface of the lower solid part 1. The flat surfaces 3 on both sides of the groove 2 are also milled into inclined surfaces 6. This process can be carried out using a CNC gantry milling machine. Its accuracy is 0.02mm. The CNC gantry milling machine uses imported tools from Sandvik, Sweden. After the two solid parts 1 are assembled together, a triangular weld area 7 is formed between the two opposing inclined surfaces 6, providing space for subsequent filler welding. After the solid parts 1 are inspected, they are cleaned and dried. First, the solid part 1 with the slot 5 at the bottom is placed on the welding table 9. Then, the support 12 is placed in the groove 2 of the solid part 1. Next, the solid part 1 with the locking block 4 is flipped onto the support 12. The two solid parts 1 are fixed using tooling, with the support 12 inside and the clamp 10 outside for installation. Figure 9 As shown, a clamp 10 is installed every 300mm. After the two solid parts 1 are clamped together with the clamp 10, the support 12 is slid to check the straightness of the hexagonal flow channel 8. The support 12 enters from one end of the hexagonal flow channel 8 and exits from the other end. It is acceptable if there is no jamming. After installation, the hexagonal flow channel 8 is welded using argon arc welding with internal cooling water. The welding is done symmetrically in sections. After the temperature cools down, the next section is welded. At the same time, symmetrical welding is added layer by layer until the entire hexagonal flow channel 8 is welded. The welding material is CHG-316 material, using TIG welding with argon protection to ensure that no other materials that come into direct contact with the liquid metal are introduced during welding. The weld is then inspected by RT after welding. Then, the hexagonal hole in the middle of the flange 11 is fitted onto the support 12. The support 12 ensures the concentricity of the flange 11 during welding. The inner side of the flange 11 contacts the end face of the pipe fitting, and welding begins to fix the flange 11. After the flange 11 is welded, the entire pipe fitting is subjected to stress-relieving heat treatment. After the heat treatment, the pipe fitting is cooled. After cooling, the support 12 is destroyed using a deep hole boring machine and the support 12 is removed. Finally, the pipe fitting is ground to obtain the hexagonal flow channel 8 pipe fitting that meets the requirements.

[0061] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Based on the technical essence of the present invention, any simple modifications, equivalent substitutions, and improvements made to the above embodiments within the spirit and principles of the present invention shall still fall within the protection scope of the present invention.

Claims

1. A manufacturing process for a hexagonal flow channel pipe fitting, characterized in that, The process includes the following steps: A1: Make two symmetrical semi-circular solid parts (1), and the two solid parts (1) are joined together to form a circular part; A2: Grooves (2) are opened on the opposite surfaces of the two solid parts (1). The grooves (2) penetrate the solid parts (1) along the length of the solid parts (1). After the two solid parts (1) are closed, a hexagonal flow channel (8) is formed in the middle. A3: The opposite surfaces of the two solid parts (1) are made into inclined surfaces (6). The inclined surfaces (6) are located on both sides of the groove (2). After the two solid parts (1) are closed, the two inclined surfaces (6) that are opposite each other form a weld area (7). A4: Weld two solid parts (1) in the weld area (7) to obtain a hexagonal flow channel (8) pipe fitting; A5: Hexagonal flow channel (8) Pipe end welding flange (11); During the process of making the inclined surface (6), a locking block (4) is formed on the bottom surface of the upper solid part (1). The locking block (4) is located on both sides of the groove (2). A slot (5) that matches the locking block (4) is formed on the top surface of the lower solid part (1). The slot (5) is located on both sides of the groove (2). After the two solid parts (1) are closed, the locking block (4) is inserted into the slot (5). Before welding the two solid parts (1), a suitable support (12) needs to be placed in the hexagonal flow channel (8). The length of the support (12) is greater than the length of the solid part (1). Before welding, place one of the solid parts (1) on the welding table (9), and then place the support (12) in the groove (2) of the solid part (1). The two ends of the support (12) are located outside the solid part (1). Then, fasten the other solid part (1) onto the solid part (1) below. Then, use multiple clamps (10) to lock and fix the two solid parts (1) and the support (12) along the length of the welding table (9).

2. The manufacturing process of a hexagonal flow channel pipe fitting according to claim 1, characterized in that, The cross section of the weld area (7) is triangular, and the included angle between the two inclined surfaces (6) is acute.

3. The manufacturing process of a hexagonal flow channel pipe fitting according to claim 1, characterized in that, The support member (12) is a hexagonal cube with a hexagonal cross section.

4. The manufacturing process of a hexagonal flow channel pipe fitting according to claim 1, characterized in that, When welding flange (11), the flange (11) has a hexagonal hole in the middle that is adapted to support member (12). The end of support member (12) passes through the hexagonal hole in the middle of flange (11). Welding begins after the inner side of flange (11) contacts the end face of pipe fitting.

5. The manufacturing process of a hexagonal flow channel pipe fitting according to claim 1, characterized in that, When welding two solid parts (1), symmetrical welding is carried out by adding layers one by one.

6. The manufacturing process of a hexagonal flow channel pipe fitting according to claim 1, characterized in that, After the flange (11) is welded, the entire pipe fitting is subjected to stress-relieving heat treatment.

7. The manufacturing process of a hexagonal flow channel pipe fitting according to claim 6, characterized in that, After heat treatment, the pipe is cooled. After cooling, the support (12) is destroyed using a deep hole boring machine. The support (12) is removed and the pipe is finally polished.

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