阅读说明：本技术 一种超大直径钢制法兰的锻造及其制造方法 (Forging and manufacturing method of steel flange with ultra-large diameter ) 是由 费新海 费爱华 于 2020-12-11 设计创作，主要内容包括：本发明公开了一种超大直径钢制法兰的锻造及其制造方法,属于超大直径钢制法兰制造方法领域,其技术方案要点是,包括以下步骤：S1、准备若干长条坯料；S2、长条坯料采用弯曲,得到弧形坯料；S3、在基板上画样；S4、去除弧形坯料多余部分；S5、依照画样将弧形坯料放置在基板之后上检查画样；S6、在弧形坯料端部加工连接坡口；S7、将弧形坯料放回到基板上；S8、采用电弧增材制造的方式将弧形坯料连接；S9、法兰整体回火去应力；S10、对法兰进行机械加工去除余量,本发明的优点在于不受到设备的限制,简化生产步骤,缩短周期长,降低生产成本,提高经济效益。(The invention discloses a forging method and a manufacturing method of an oversized-diameter steel flange, belonging to the field of manufacturing methods of oversized-diameter steel flanges, and the technical scheme is characterized by comprising the following steps: s1, preparing a plurality of strip blanks; s2, bending the strip blank to obtain an arc blank; s3, drawing a sample on the substrate; s4, removing the redundant part of the arc-shaped blank; s5, placing the arc-shaped blank on the substrate according to the drawing sample and then checking the drawing sample; s6, processing a connecting groove at the end of the arc-shaped blank; s7, putting the arc-shaped blank back on the base plate; s8, connecting the arc-shaped blanks in an electric arc additive manufacturing mode; s9, tempering and destressing the whole flange; s10, machining the flange to remove allowance, and the method has the advantages of being free from the limitation of equipment, simplifying production steps, shortening the period, reducing the production cost and improving the economic benefit.)

1. A forging and manufacturing method of an ultra-large diameter steel flange is characterized by comprising the following steps: s1, preparing a plurality of strip blanks; s2, bending the strip blank to obtain an arc blank; s3, drawing a sample on the substrate; s4, removing the redundant part of the arc-shaped blank; s5, placing the arc-shaped blank on the substrate according to the drawing sample and then checking the drawing sample; s6, processing a connecting groove at the end of the arc-shaped blank; s7, putting the arc-shaped blank back on the base plate; s8, connecting the arc-shaped blanks in an electric arc additive manufacturing mode; s9, tempering and destressing the whole flange; and S10, machining the flange to remove allowance.

2. The forging and manufacturing method of an oversized-diameter steel flange according to claim 1, characterized in that: in step S1, the circumference of the flange outer diameter is first calculated, and the circumference is divided into several segments, each segment being the length of the long piece.

3. The forging and manufacturing method of an oversized-diameter steel flange according to claim 1, characterized in that: in step S6, the angle range of the connecting groove forming opening of two adjacent arc-shaped blanks is 45 to 50 °.

4. The forging and manufacturing method of an oversized-diameter steel flange according to claim 1, characterized in that: in step S5, when the arc-shaped blanks are laid out according to the drawing layout, the seam between the arc-shaped blanks is ensured to be less than 1 mm.

5. The forging and manufacturing method of an oversized-diameter steel flange according to claim 1, characterized in that: in step S8, the method includes the steps of: 1. preparing equipment, wires and protective gas; 2. analyzing the connection groove layer by layer to establish a model, and planning an additive path; 3. and filling layer by layer according to the model, and fully filling the connection groove with the support.

6. The forging and manufacturing method of an oversized-diameter steel flange according to claim 5, wherein the forging and manufacturing method comprises the following steps: in step 1, 316L stainless steel is selected as the wire material, and a mixed gas of argon and nitrogen is selected as the protective gas.

7. The forging and manufacturing method of an oversized-diameter steel flange according to claim 5, wherein the forging and manufacturing method comprises the following steps: in step 3, the filling path of each layer is filled line by line along the width direction.

8. The forging and manufacturing method of an oversized-diameter steel flange according to claim 5, wherein the forging and manufacturing method comprises the following steps: in step 3, the welding speed is 0.35-0.5m/min, the welding current is controlled at 120-140A, and the wire feeding speed is controlled at 80-100 mm/s.

9. The forging and manufacturing method of an oversized-diameter steel flange according to claim 1, characterized in that: in step S9, the flange is sent into a furnace for heating and tempering, the temperature range is controlled at 1080-1120 ℃, the temperature is kept for 1-1.5h, and then the oil is cooled to the room temperature.

Technical Field

The invention relates to the field of manufacturing methods of steel flanges with ultra-large diameters, in particular to forging of steel flanges with ultra-large diameters and a manufacturing method of the steel flanges.

Background

The flange is a conventional connection. From light industries to heavy industries. Especially, in the fields of hydroelectric power generation, aerospace, marine ships and the like, the flange with an ultra-large diameter is required to be used, and the flange has harsh working conditions, so that the flange has higher performance requirements on the performance of the flange.

The traditional large flange part is formed by adopting modes of steel ingot smelting, casting, forging and the like, and is subjected to auxiliary heat treatment and final machining, the final performance reaches the technical requirement, but the traditional method has various manufacturing procedures and long production period, and has the size requirement that large-scale related equipment can produce, and manufacturers with general equipment conditions cannot produce parts, so that the production cost of a single part is high, and the economic benefit is poor.

Disclosure of Invention

The invention aims to provide a forging method of an oversized-diameter steel flange and a manufacturing method thereof, which have the advantages of being free from the limitation of equipment, simplifying production steps, shortening the period, reducing the production cost and improving the economic benefit.

The technical purpose of the invention is realized by the following technical scheme:

a forging and manufacturing method of an ultra-large diameter steel flange comprises the following steps: s1, preparing a plurality of strip blanks; s2, bending the strip blank to obtain an arc blank; s3, drawing a sample on the substrate; s4, removing the redundant part of the arc-shaped blank; s5, placing the arc-shaped blank on the substrate according to the drawing sample and then checking the drawing sample; s6, processing a connecting groove at the end of the arc-shaped blank; s7, putting the arc-shaped blank back on the base plate; s8, connecting the arc-shaped blanks in an electric arc additive manufacturing mode; s9, tempering and destressing the whole flange; and S10, machining the flange to remove allowance.

Further, in step S1, the circumference of the flange outer diameter is first calculated, and the circumference is divided into several segments, and the length of each segment is the length of the long billet.

Further, in step S6, the angle range of the connecting groove forming opening of two adjacent arc-shaped blanks is 45-50 °.

Further, in step S5, when the arc-shaped blanks are laid out according to the layout, the seam between the arc-shaped blanks is ensured to be less than 1 mm.

Further, in step S8, the method includes the following steps: 1. preparing equipment, wires and protective gas; 2. analyzing the connection groove layer by layer to establish a model, and planning an additive path; 3. and filling layer by layer according to the model, and fully filling the connection groove with the support.

Further, in step 1, 316L stainless steel is selected as the wire material, and a mixed gas of argon and nitrogen is selected as the protective gas.

Further, in step 3, the filling path of each layer is filled row by row along the width direction.

Further, in step 3, the welding speed is 0.35-0.5m/min, the welding current is controlled at 120-140A, and the wire feeding speed is controlled at 80-100 mm/s.

Further, in step S9, the flange is sent into a furnace for heating and tempering, the temperature range is controlled at 1080-1120 ℃, the temperature is kept for 1-1.5h, and then the flange is oil-cooled to the room temperature.

In conclusion, the invention has the following beneficial effects:

1. aiming at the ultra-large flange with the diameter of more than 6m, the manufacturing does not need to depend on a large-scale press, the requirement on equipment is low, the production cost is reduced, and the economic benefit is improved;

2. the adoption of the electric arc additive technology connects the multiple sections of arc-shaped blanks into a whole, so that the size precision of the joint can be obvious, and the replacement of manual welding greatly shortens the working time.

Drawings

FIG. 1 is a schematic representation of the steps in the forging of an oversized-diameter steel flange and a method of making the same;

fig. 2 is a schematic view of the structure of the connection groove.

Detailed Description

The present invention will be described in further detail with reference to the accompanying drawings.

In which like parts are designated by like reference numerals. It should be noted that the terms "front," "back," "left," "right," "upper" and "lower" used in the following description refer to directions in the drawings, and the terms "bottom" and "top," "inner" and "outer" refer to directions toward and away from, respectively, the geometric center of a particular component.

Example 1: a forging method of an ultra-large diameter steel flange and a manufacturing method thereof are disclosed as shown in figure 1, and comprise the following steps: s1, preparing a plurality of long-strip blanks, wherein the blanks are 316L ultra-low carbon stainless steel. The operator calculates the perimeter of the flange outer diameter, the perimeter is divided into a plurality of sections, the length of each section is the length of the long-strip blank, and finally the length is obtained according to the calculation. In this example, the size of the manufactured flange is phi 9800 mm/phi 9100mm 640mm, and the designed flange is divided into 4 sections.

And S2, bending the strip blank to obtain an arc blank. The arc-shaped blank correspondingly has a central angle of 90 degrees.

And S3, drawing a pattern on the substrate. The substrate is made of the same material as the blank. The substrate is drawn according to the 1: 1 flange.

And S4, removing the redundant parts of the arc-shaped blanks in a line machining mode, and numbering each section of arc-shaped blanks.

And S5, placing the arc-shaped blanks on the base plate according to the drawing, and checking the drawing to ensure that the seam between the arc-shaped blanks is less than 1 mm.

And S6, as shown in figure 2, machining a pair of connecting grooves at the end part of the arc-shaped blank, wherein the connecting grooves are symmetrically arranged inside and outside. The angle range of the opening formed by the connecting grooves of two adjacent arc-shaped blanks is 45-50 degrees.

S7, the arc-shaped blank is placed back on the substrate and the pattern lines are rechecked.

S8, connecting the arc-shaped blanks in an arc additive manufacturing mode, wherein the arc-shaped blanks specifically comprise:

1. preparing equipment, wires and protective gas. Wherein, ABB welding robot and positioner are selected as the equipment, 316L stainless steel is selected as wire material, and mixed gas of argon and nitrogen is selected as protective gas.

2. And analyzing the connection groove layer by layer to establish a model, and planning an additive path.

3. And filling layer by layer from bottom to top according to the model, and fully filling the connection groove with the support. The filling path of each layer is filled line by line along the width direction. Welding parameters are as follows: the welding speed is 0.35-0.5m/min, the welding current is controlled at 120-140A, and the wire feeding speed is controlled at 80-100 mm/s.

And S9, tempering and destressing the whole flange. And (3) feeding the flange into a furnace by a worker for heating, heating to 1080 ℃, controlling the heating rate at 120 ℃/min, keeping the temperature for 1h after the target temperature is reached, and cooling the oil to the room temperature.

And S10, machining the flange to remove allowance. And finally, carrying out ultrasonic nondestructive testing on the flange, wherein the flange part meets the standards of NB1T47008-2010 and 70BJ 026-2010.

Example 2: the difference from the example 1 is that in step S9, the worker heats the flange in a furnace, the temperature is raised to 1100 ℃, the temperature raising rate is controlled at 100 ℃/min, the temperature is kept for 1h15min after the target temperature is reached, and then the oil is cooled to the room temperature.

Example 3: the difference from the example 1 is that in step S9, the worker heats the flange in the furnace to 1120 ℃, the heating rate is controlled at 150 ℃/min, the flange is kept warm for 1h30min after reaching the target temperature, and then the flange is cooled to the room temperature.

The present embodiment is only for explaining the present invention, and it is not limited to the present invention, and those skilled in the art can make modifications of the present embodiment without inventive contribution as needed after reading the present specification, but all of them are protected by patent law within the scope of the claims of the present invention.