Manufacturing method of black metal elbow

Abstract

The invention relates to the technical field of metal elbow production, and provides a manufacturing method of a black metal elbow, which comprises the following steps of material selection, pre-deformation treatment, blanking, heating, forming, bending, heat treatment, surface treatment and intelligent detection. According to the manufacturing method of the black metal elbow, through a series of process optimization and innovation, the material performance, the forming quality and the surface quality of the elbow are remarkably improved, and the quality and reliability of a product are ensured. The method has the advantages of being advanced in process, easy and convenient to operate, controllable in quality and the like, can meet the high-quality requirements of different fields for the black metal elbow, and has wide application prospects and market value. And meanwhile, the implementation of the method contributes to promoting the technical progress and industrial upgrading of the ferrous metal processing industry, and makes positive contributions to the development of related fields.

Description

Technical Field

[0001] The present invention relates to the technical field of metal elbow production, and particularly relates to a manufacturing method for ferrous metal elbows. Background Art

[0002] In modern industry, ferrous metal elbows, as an important part of pipeline systems, are widely used in fields such as petroleum, chemical industry, natural gas, and electric power. However, in the traditional manufacturing process of ferrous metal elbows, there are often some problems that limit the quality and performance of the elbows.

[0003] In the traditional manufacturing method, the chemical composition may not be strictly controlled during material selection, resulting in unstable material properties and affecting the service life and reliability of the elbows. During the forming process, the lack of effective pre-deformation treatment and advanced forming techniques easily causes poor material fluidity and unevenness, increasing the forming difficulty and the risk of defect generation. In addition, the temperature control during the heating process is not precise enough, which may lead to overheating or insufficient plasticity of the material, affecting subsequent processing and performance.

[0004] In the bending process, the traditional process may adopt a single bending method, which easily causes stress concentration and uneven deformation, thus affecting the shape accuracy and mechanical properties of the elbows. The heat treatment process may also be imperfect and unable to effectively eliminate residual stress and improve the microstructure and properties of the material.

[0005] In terms of surface treatment, the traditional method may have problems such as uneven sandblasting, poor pickling effect, and low polishing quality, resulting in poor surface quality of the elbows, easy corrosion and wear, and reduced service life and fluid transportation efficiency.

[0006] In terms of quality inspection, the traditional inspection means may not be comprehensive and intelligent enough, making it difficult to accurately detect and evaluate the various properties of the elbows and unable to ensure that the products meet relevant standards and design requirements.

[0007] Therefore, this solution specifically proposes a manufacturing method for ferrous metal elbows to solve the above problems. Summary of the Invention

[0008] To overcome the defects of the prior art, the purpose of the present invention is to provide a manufacturing method for ferrous metal elbows.

[0009] To achieve the above object, the technical solution of the present invention is realized as follows: A manufacturing method for ferrous metal elbows, comprising the following steps:

[0010] Material selection: Carefully select suitable ferrous metal materials, such as carbon steel or alloy steel, etc. The chemical composition of the ferrous metal materials should strictly comply with specific standards, and the carbon content should be in the range of [0.2% - 0.5%];

[0011] Pre - deformation treatment: The blank is subjected to pre - deformation treatment. Through a specially designed mechanical device, a force of a certain magnitude and duration is applied to the blank along a specific direction and path, causing micro - strains to occur inside the blank. This pre - deformation can effectively improve the material fluidity and uniformity during the subsequent forming process, reducing the forming difficulty and the possibility of defect generation;

[0012] Blank cutting: According to the precise design dimensions of the elbow, a high - precision cutting device is used to cut the pre - deformed ferrous metal material into the required blank shape and size. The cutting accuracy should be controlled within [±0.5mm] to ensure the dimensional accuracy and consistency of the blank;

[0013] Heating: The blank is carefully placed into an advanced heating furnace for heating. The heating temperature needs to be precisely controlled between [800℃ - 1000℃]. The temperature stability is maintained through precise temperature sensors and control systems to ensure that the blank reaches good plasticity while avoiding a decline in material properties caused by overheating;

[0014] Forming: A special elbow - forming die is used to stamp or extrude the heated blank to initially form the shape of the elbow. During the forming process, an ultrasonic vibration - assisted technology is innovatively introduced. An ultrasonic vibration generator generates vibrations with a specific frequency and amplitude, which are transmitted to the die and the blank through a transmission device, promoting more uniform material flow in the die, reducing material accumulation and defect formation, and at the same time optimizing the microstructure to improve the forming quality;

[0015] Bending: Advanced pipe - bending equipment, such as a high - precision hydraulic pipe - bending machine or a numerical - control pipe - bending machine, is used to bend the initially formed elbow. The bending angle and curvature radius need to be precisely adjusted strictly according to the design requirements. The segmented progressive bending process is adopted during bending, that is, the bending process is divided into multiple stages, and the bending force is applied gradually to reduce stress concentration and non - uniform deformation. At the same time, a stress - strain monitoring device is used to monitor the stress distribution during the bending process in real - time to adjust the bending parameters in a timely manner to ensure the quality and performance of the elbow;

[0016] Heat treatment: The bent elbow is subjected to heat treatment to effectively eliminate residual stresses and improve the microstructure and properties of the material. The heat - treatment process includes heating the elbow to [900℃ - 1100℃], holding for [30min - 60min], and then cooling. During the cooling process, a gradient cooling method is adopted, that is, a relatively fast cooling rate is first used for preliminary cooling, and then the cooling rate is gradually reduced to reduce the generation of thermal stress and improve the stability of material properties;

[0017] Surface treatment: The surface of the elbow is carefully treated to remove scale and other impurities, improving the surface quality. The surface treatment methods include sandblasting with a rotary sandblasting head to make the sand grains more evenly sprayed onto the surface of the elbow, improving the sandblasting uniformity and efficiency. The sand grain size is selected in the range of [0.5mm - 1mm]. At the same time, pickling is carried out with a pickling solution of specific composition and concentration to remove surface rust and other contaminants. Finally, polishing is performed with a high-quality polishing wheel, and the polishing wheel material can be [rubber or wool] to obtain a smooth and bright surface;

[0018] Intelligent detection: Use highly intelligent detection equipment to conduct a comprehensive quality inspection on the fabricated ferrous metal elbow, including visual inspection using a high-definition camera, dimensional measurement using a high-precision measuring instrument, and mechanical property tests such as tensile test, hardness test, and impact test using professional mechanical property testing equipment. The detection data is fed back in real time and compared with the standard data for analysis, and an inspection report is automatically generated to ensure that the elbow meets the relevant standards and design requirements.

[0019] Preferably, the ferrous metal material is carbon steel or alloy steel.

[0020] Preferably, in the heating step, induction heating or flame heating is adopted.

[0021] Preferably, in the forming step, the pressure for stamping or extrusion forming is [10MPa - 20MPa].

[0022] Preferably, in the bending step, a hydraulic pipe bender or a numerical control pipe bender is used as the pipe bending equipment.

[0023] Preferably, in the heat treatment step, the cooling method is air cooling or water cooling.

[0024] Preferably, in the heat treatment step, in the surface treatment step, the sand grain size for sandblasting is [0.5mm - 1mm], the pickling solution is hydrochloric acid with a concentration of [10% - 15%], and the polishing wheel material for polishing is [rubber or wool].

[0025] Preferably, in the heat treatment step, in the intelligent detection step, the mechanical property tests include tensile test, hardness test, and impact test.

[0026] The beneficial effects of the present invention are reflected in:

[0027] Improving material properties:

[0028] By strictly selecting ferrous metal materials such as carbon steel or alloy steel with a carbon content in the range of [0.2% - 0.5%], the quality of the base material of the elbow is ensured, providing good performance guarantee for subsequent processing and use.

[0029] The pre - deformation treatment induces micro - strains inside the blank, effectively improving the material fluidity and uniformity during the subsequent forming process, reducing the forming difficulty, decreasing the possibility of defect generation, and thus enhancing the overall performance of the material.

[0030] Precisely control the heating temperature between [800°C - 1000°C], enabling the blank to achieve good plasticity while avoiding performance degradation caused by overheating, ensuring the stability of the material properties of the elbow during the processing.

[0031] The heat treatment process can effectively eliminate residual stresses, improve the microstructure and properties of the material, and further enhance the strength, toughness, and durability of the elbow.

[0032] Optimize the forming quality:

[0033] Use high - precision cutting equipment to cut the blank into the required shape and size, with the cutting accuracy controlled within [±0.5mm], ensuring the dimensional accuracy and consistency of the blank, and providing a good foundation for the subsequent forming process.

[0034] Introduce ultrasonic vibration - assisted technology during the forming process, which promotes more uniform flow of the material in the mold, reduces material accumulation and defect formation, and simultaneously optimizes the microstructure, significantly improving the forming quality.

[0035] Adopt a segmented progressive bending process during bending, gradually applying the bending force, reducing stress concentration and non - uniform deformation, and improving the shape accuracy and mechanical properties of the elbow.

[0036] Enhance the surface quality:

[0037] During the surface treatment process, use a rotary sand - blasting head for sand - blasting treatment, making the sand grains more evenly sprayed onto the surface of the elbow, improving the sand - blasting uniformity and efficiency.

[0038] Select sand grains of appropriate particle size ([0.5mm - 1mm]) and pickling solutions with specific compositions and concentrations for pickling, effectively removing the surface scale, rust, and other contaminants.

[0039] Finally, use a high - quality polishing wheel (made of rubber or wool) for polishing to obtain a smooth and bright surface, which not only improves the appearance quality of the elbow but also reduces fluid resistance and extends the service life.

[0040] Ensure the product quality:

[0041] Use highly intelligent detection equipment to conduct a comprehensive quality inspection on the fabricated ferrous metal elbows, including appearance inspection, dimensional measurement, and mechanical property testing, etc., ensuring that the elbows meet the relevant standards and design requirements.

[0042] The detected data is fed back in real time and compared with the standard data for analysis, and a detection report is automatically generated, achieving strict control over product quality and improving the reliability and stability of the product.

[0043] In summary, the manufacturing method of the ferrous metal elbow of the present invention significantly improves the material properties, forming quality and surface quality of the elbow through a series of process optimizations and innovations, ensuring the quality and reliability of the product. This method has the advantages of advanced technology, simple operation, and controllable quality, can meet the high-quality requirements for ferrous metal elbows in different fields, and has broad application prospects and market value. At the same time, the implementation of the present invention helps to promote the technological progress and industrial upgrading of the ferrous metal processing industry and make positive contributions to the development of related fields. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] In the drawings:

[0045] Figure 1 is a flowchart of the manufacturing method of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0046] The present invention will be further described in detail below with reference to the drawings and embodiments. Obviously, the described embodiments are only a part of the embodiments of the invention, rather than all of the embodiments. Without conflict, the embodiments in the present application and the features in the embodiments can be combined with each other. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the invention without creative efforts shall fall within the scope of protection of the invention.

[0047] Please refer to the attached drawings of the specification Figure 1 , the present invention provides a manufacturing method for a ferrous metal elbow, including the following steps:

[0048] Material selection: Select carbon steel as the ferrous metal material, and its chemical composition strictly complies with specific standards, with a carbon content of 0.3%.

[0049] Pre-deformation treatment: Apply a force to the blank through a specially designed mechanical device along a specific direction and path. The magnitude of the force is 10 kN, and the duration is 10 s, so that microscopic strains are generated inside the blank.

[0050] Blanking: According to the design dimensions of the elbow, use a high-precision laser cutting device to cut the pre-deformed carbon steel material into the required blank shape and size, and the cutting accuracy is controlled within ±0.3 mm.

[0051] Heating: Place the blank in an induction heating furnace for heating, and the heating temperature is precisely controlled at 900 °C. The temperature stability is maintained through a temperature sensor and a control system.

[0052] Forming: Use a special elbow forming die to stamp the heated blank. The stamping pressure is 15 MPa. During the forming process, introduce ultrasonic vibration assistance technology. The ultrasonic vibration generator generates vibrations with a frequency of 20 kHz and an amplitude of 0.1 mm, which are transmitted to the die and the blank through a transmission device.

[0053] Bending: Use a high-precision hydraulic pipe bender to bend the preliminarily formed elbow. The bending angle and curvature radius are precisely adjusted strictly according to the design requirements. Adopt a segmented progressive bending process, divide the bending process into 5 stages, and gradually apply the bending force. During the bending process, use a stress-strain monitoring device to monitor the stress distribution in the bending process in real time and adjust the bending parameters in a timely manner.

[0054] Heat treatment: Conduct heat treatment on the bent elbow. Heat the elbow to 1000 °C, hold for 40 min, and then cool it. During the cooling process, adopt a gradient cooling method. First, conduct preliminary cooling at a relatively fast cooling rate (such as water cooling), and then gradually reduce the cooling rate (such as air cooling) to reduce the generation of thermal stress and improve the stability of the material properties.

[0055] Surface treatment: Treat the surface of the elbow to remove the oxide scale and other impurities. Use a rotary sandblasting head for sandblasting treatment. The sand grain size is 0.8 mm to make the sand grains spray more evenly on the surface of the elbow. Use a hydrochloric acid pickling solution with a concentration of 12% for pickling to remove the rust and other contaminants on the surface. Finally, use a polishing wheel made of rubber material for polishing to obtain a smooth and bright surface.

[0056] Intelligent detection: Use highly intelligent detection equipment to conduct a comprehensive quality inspection on the fabricated ferrous metal elbow. Use a high-definition camera for appearance inspection, use a high-precision measuring instrument for dimension measurement, and use professional mechanical property testing equipment for mechanical property tests such as tensile test, hardness test, and impact test. The detection data is fed back in real time and compared and analyzed with the standard data, and a detection report is automatically generated to ensure that the elbow meets the relevant standards and design requirements.

[0057]

Example 2

[0058] A manufacturing method for a ferrous metal elbow, the specific steps are as follows:

[0059] Material selection: Select alloy steel as the ferrous metal material, its carbon content is 0.4%, and the chemical composition meets specific standards.

[0060] Pre-deformation treatment: Use a special mechanical device to apply a force of 8 kN to the blank in a specific direction for a duration of 8 s to generate microscopic strain inside the blank.

[0061] Blanking: According to the precise design dimensions of the elbow, use high-precision plasma cutting equipment to cut the pre-deformed alloy steel material into the required blank shape and size, and control the cutting accuracy within ±0.4mm.

[0062] Heating: Put the blank into a flame heating furnace for heating, accurately control the heating temperature at 850°C, and use precise temperature sensors and control systems to maintain the temperature stability.

[0063] Forming: Use a special elbow forming die to extrude and form the heated blank, and the extrusion pressure is 12MPa. During the forming process, use ultrasonic vibration assistance technology. The ultrasonic vibration generator generates vibrations with a frequency of 18kHz and an amplitude of 0.08mm, and transmits them to the die and the blank through a transmission device.

[0064] Bending: Use a numerical control pipe bender to bend the preliminarily formed elbow, and accurately adjust the bending angle and curvature radius strictly according to the design requirements. Adopt a segmented progressive bending process, divide the bending process into 4 stages, and gradually apply bending force. During the bending process, use a stress and strain monitoring device to monitor the stress distribution status during bending in real time, so as to adjust the bending parameters in time.

[0065] Heat treatment: Perform heat treatment on the bent elbow, heat the elbow to 950°C, hold for 35min, and then cool. The cooling process adopts a gradient cooling method. First, use a faster cooling speed (such as air cooling) for preliminary cooling, and then gradually slow down the cooling speed (such as natural cooling) to reduce the generation of thermal stress and improve the stability of material properties.

[0066] Surface treatment: Treat the surface of the elbow to remove oxide scales and other impurities. Use a rotary sandblasting head for sandblasting, with the sand grain size of 0.6mm, so that the sand grains are evenly sprayed on the surface of the elbow. Use a pickling solution of hydrochloric acid with a concentration of 10% for pickling to remove rust and contaminants on the surface. Finally, use a polishing wheel made of wool for polishing to obtain a smooth surface.

[0067] Intelligent detection: Use intelligent detection equipment to conduct a comprehensive quality inspection on the finished ferrous metal elbow. Conduct appearance inspection through a high-definition camera, use high-precision measuring instruments for dimensional measurement, and use professional mechanical property testing equipment for mechanical property tests such as tensile test, hardness test, and impact test. The detection data is fed back in real time and compared and analyzed with the standard data, and a detection report is automatically generated to ensure that the elbow meets relevant standards and design requirements.

[0068]

Example 3

[0069] A manufacturing method of a ferrous metal elbow, comprising the following steps:

[0070] Material selection: Carbon steel is selected as the ferrous metal material with a carbon content of 0.2%, and its chemical composition meets specific standards.

[0071] Pre - deformation treatment: Through a specially designed mechanical device, a force of 6 kN is applied to the blank along a specific direction for a duration of 6 s, prompting the generation of micro - strains inside the blank.

[0072] Blanking: According to the design dimensions of the elbow, the pre - deformed carbon steel material is cut into the required blank shape and size using a high - precision water jet cutting device, and the cutting accuracy is controlled within ±0.2 mm.

[0073] Heating: The blank is placed in an induction heating furnace for heating, and the heating temperature is precisely controlled at 800 °C. The temperature stability is maintained through a temperature sensor and a control system.

[0074] Forming: A special elbow forming die is used to stamp - form the heated blank, and the stamping pressure is 10 MPa. During the forming process, an ultrasonic vibration - assisted technology is introduced. The ultrasonic vibration generator generates vibrations with a frequency of 15 kHz and an amplitude of 0.05 mm, which are transmitted to the die and the blank through a transmission device.

[0075] Bending: A hydraulic pipe bender is used to bend the preliminarily formed elbow. The bending angle and the curvature radius are precisely adjusted strictly according to the design requirements. A segmented progressive bending process is adopted, and the bending process is divided into 3 stages, gradually applying the bending force. During the bending process, a stress - strain monitoring device is used to monitor the stress distribution in real - time, and the bending parameters are adjusted in a timely manner.

[0076] Heat treatment: The bent elbow is heat - treated. The elbow is heated to 900 °C, held for 30 min, and then cooled. During the cooling process, a gradient cooling method is adopted. First, it is initially cooled at a relatively fast cooling rate (such as oil cooling), and then the cooling rate is gradually reduced (such as air cooling) to reduce the generation of thermal stress and improve the stability of the material properties.

[0077] Surface treatment: The surface of the elbow is treated to remove the oxide scale and other impurities. A rotary sandblasting head is used for sandblasting treatment, and the sand grain size is 0.5 mm, so that the sand grains are sprayed more evenly on the surface of the elbow. A pickling solution of hydrochloric acid with a concentration of 15% is used for pickling to remove the rust and other pollutants on the surface. Finally, a polishing wheel made of rubber material is used for polishing to obtain a smooth and bright surface.

[0078] Intelligent Detection: Use highly intelligent detection equipment to conduct a comprehensive quality inspection on the completed ferrous elbows. Use high-definition cameras for appearance inspection, high-precision measuring instruments for dimension measurement, and professional mechanical property testing equipment for mechanical property tests such as tensile tests, hardness tests, and impact tests. The detection data is fed back in real time and compared with the standard data for analysis, and a detection report is automatically generated to ensure that the elbows meet the relevant standards and design requirements.

[0079] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A method for manufacturing a ferrous metal elbow, characterized in that: The following steps are involved: Material selection: Select suitable ferrous metal materials, such as carbon steel or alloy steel, etc. The chemical composition of the ferrous metal materials must strictly meet specific standards, and the carbon content should be [0.2%-0.5%]; Pre-deformation treatment: The blank is pre-deformed by applying a force of a certain magnitude and duration to the blank along a specific direction and path through a specially designed mechanical device, so as to produce microscopic strain inside the blank; Cutting: According to the precise design size of the elbow, use high-precision cutting equipment to cut the pre-deformed ferrous metal material into the required billet shape and size. The cutting accuracy should be controlled within [±0.5mm] to ensure the dimensional accuracy and consistency of the billet; Heating: Carefully place the blank into an advanced heating furnace for heating. The heating temperature must be precisely controlled between [800℃-1000℃], and the temperature stability is maintained through precise temperature sensors and control systems; Forming: A special elbow forming die is used to stamp or extrude the heated blank to initially form the shape of the elbow. Ultrasonic vibration auxiliary technology is innovatively introduced during the forming process, and an ultrasonic vibration generator is used to generate vibrations of a specific frequency and amplitude, which are transmitted to the die and the blank through a transmission device; Bending: Use advanced bending equipment, such as high-precision hydraulic pipe bender or CNC pipe bender, to bend the initially formed elbow. The bending angle and curvature radius must be precisely adjusted according to the design requirements. The bending process is divided into multiple stages, and the bending force is gradually applied. At the same time, the stress distribution during the bending process is monitored in real time using a stress and strain monitoring device. Heat treatment: The elbow after bending is heat treated to effectively eliminate residual stress and improve the structure and performance of the material. The heat treatment process includes heating the elbow to [900℃-1100℃], keeping it warm for [30min-60min], and then cooling it. The cooling process adopts a gradient cooling method, that is, a faster cooling rate is used for preliminary cooling, and then the cooling rate is gradually reduced; Surface treatment: The surface of the elbow is carefully treated to remove scale and other impurities and improve the surface quality. The surface treatment method includes sandblasting with a rotary sandblasting head, and the sand particle size is selected in [0.5mm-1mm]. At the same time, pickling is carried out with a pickling solution of specific composition and concentration, and finally polishing is carried out with a high-quality polishing wheel. The polishing wheel material can be [rubber or wool]; Intelligent testing: Use highly intelligent testing equipment to conduct comprehensive quality inspection on the completed ferrous metal elbows, including appearance inspection using high-definition cameras, dimensional measurement using high-precision measuring instruments, and mechanical property tests such as tensile tests, hardness tests, and impact tests using professional mechanical property testing equipment. The test data is fed back in real time and compared with standard data for analysis, and the test report is automatically generated.

2. The method for manufacturing a ferrous metal elbow according to claim 1, characterized in that: The ferrous metal material is carbon steel or alloy steel.

3. The method for manufacturing a ferrous metal elbow according to claim 1, characterized in that: In the heating step, induction heating or flame heating is adopted.

4. The method for manufacturing a ferrous metal elbow according to claim 1, characterized in that: In the molding step, the pressure of the punching or extrusion molding is [10MPa-20MPa].

5. The method for manufacturing a ferrous metal elbow according to claim 1, characterized in that: In the bending step, the pipe bending equipment adopts a hydraulic pipe bender or a CNC pipe bender.

6. The method for manufacturing a ferrous metal elbow according to claim 1, characterized in that: In the heat treatment step, the cooling method is air cooling or water cooling.

7. The method for manufacturing a ferrous metal elbow according to claim 1, characterized in that: In the heat treatment step, in the surface treatment step, the sand particle size of the sand blasting treatment is [0.5mm-1mm], the pickling solution is hydrochloric acid with a concentration of [10%-15%], and the polishing wheel material used for polishing is [rubber or wool].

8. The method for manufacturing a ferrous metal elbow according to claim 1, characterized in that: In the heat treatment step, in the intelligent detection step, the mechanical properties tests include tensile test, hardness test and impact test.

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