阅读说明：本技术 大型变截面结构件高强度板材无痕成形工艺 (Traceless forming process for high-strength plate of large variable cross-section structural part ) 是由 陈建红 肖伟 陶翠莹 于 2020-12-22 设计创作，主要内容包括：本发明公开了大型变截面结构件高强度板材无痕成形工艺,包括以下步骤：S1、准备材料：准备底座尺寸为底方形14m*12m,上圆形直径14m,高度5.4m,准备板材4块,平直段两块,板材为StE690高强度板材,板厚30mm～60mm,精度为成品的轮廓线偏差不超过理论中心线5mm；该大型变截面结构件高强度板材无痕成形工艺通过成型模具设计以及制造保证了板材模具的无误差,通过激光制作出对应的样板制作检验样板,并根据图纸对样板进行划线和压弯操作,并在划线和压弯后,采用多台行车起吊、翻身,平稳吊放在预先划好成形图的平台上进行吊装操作,最终由结构件上下口的尺寸特征,在平台上面1:1划线,然后使用水平仪对工件进行找平并使用全站仪对产品进行测量。(The invention discloses a traceless forming process for a high-strength plate of a large variable cross-section structural member, which comprises the following steps of: s1, preparation materials: preparing a base with the size of a square bottom of 14m by 12m, an upper circular with the diameter of 14m and the height of 5.4m, preparing 4 plates and two flat sections, wherein the plates are StE690 high-strength plates, the plate thickness is 30-60 mm, and the precision is that the contour line deviation of a finished product does not exceed 5mm of a theoretical central line; the large variable cross-section structural member high-strength plate traceless forming process ensures that a plate mold is error-free through design and manufacture of a forming mold, a corresponding sample plate is manufactured through laser to manufacture a test sample plate, the sample plate is scribed and bent according to a drawing, a plurality of traveling cranes are adopted to lift and turn over after scribing and bending, the test sample plate is stably hung on a platform with a formed drawing scribed in advance to carry out lifting operation, finally, the upper opening and the lower opening of a structural member are scribed at a ratio of 1:1 on the platform, a workpiece is leveled by a level gauge, and a total station is used for measuring a product.)

1. The traceless forming process of the high-strength plate of the large variable cross-section structural member is characterized by comprising the following steps of:

s1, preparation materials: preparing a base with the size of a square bottom of 14m by 12m, an upper circular with the diameter of 14m and the height of 5.4m, preparing 4 plates and two flat sections, wherein the plates are StE690 high-strength plates, the plate thickness is 30-60 mm, and the precision is that the contour line deviation of a finished product does not exceed 5mm of a theoretical central line;

s2, designing and manufacturing a forming die: designing a proper upper die and a proper lower die by combining the molding height difference of the two ends according to the drawing requirements, simulating the molding of the material by adopting simulation software after the design is finished, and producing and manufacturing after the result is correct;

s3, manufacturing a test template: after the appearance data of the product is obtained, a corresponding sample plate is manufactured by laser, multiple sample plates are designed to check the sizes of the upper opening, the lower opening and the waist line position, and the sample plates are used for checking during the completion;

s4, scribing: marking according to a drawing, wherein in the marking process, each line of the subsequent forming precision is checked, the error is controlled within-1 mm, and the marking density depends on the size of a product and the forming difficulty;

s5, bending: in the bending process, each bending is accurately measured, the upper die is centered by using laser, and the contact line of the die is accurately pressed on the scribing position of a processed workpiece;

s6, hoisting: after the workpiece is bent, in order to prevent the deformation caused by lifting, a plurality of traveling cranes are adopted for lifting and turning over, and the workpiece is stably lifted and placed on a platform with a pre-marked forming diagram;

s7, correction and detection: 1:1 marking on a platform according to the size characteristics of upper and lower openings of a structural member, lifting a workpiece onto the platform after marking is finished, enabling the upper and lower openings of the workpiece to be basically consistent with the marking in projection, leveling the workpiece by using a level instrument, and measuring a product by using a total station after leveling is finished;

s8, transportation: the parts are irregular in shape, more stress exists in the parts, and special brackets are adopted for fixing and transporting during transportation.

2. The traceless forming process of the high-strength plate of the large variable cross-section structural part according to claim 1, wherein the traceless forming process comprises the following steps: in S2, the die is made of a high-strength alloy material, and after the die is finished, the die is dipped in fire to improve the surface hardness, and then ground.

3. The traceless forming process of the high-strength plate of the large variable cross-section structural part according to claim 1, wherein the traceless forming process comprises the following steps: and S3, dividing the structure into 1-3 layers according to the equipment drawing of a hoisting equipment factory.

4. The traceless forming process of the high-strength plate of the large variable cross-section structural part according to claim 1, wherein the traceless forming process comprises the following steps: and S7, splicing the whole base after the plurality of plates are manufactured and measured, thereby completing the work task of the base.

5. The traceless forming process of the high-strength plate of the large variable cross-section structural part according to claim 1, wherein the traceless forming process comprises the following steps: in S7, when an error is found in the measurement, the workpiece needs to be corrected again, and the workpiece is corrected by using a method of continuing to adjust the bending machine or by using a firer until the dimensional accuracy meeting the requirements of the drawing is achieved.

6. The traceless forming process of the high-strength plate of the large variable cross-section structural part according to claim 1, wherein the traceless forming process comprises the following steps: in S5, the bending angle is determined by installing a scanner in the bending machine, the scanner emitting a beam to a straight edge of the bent portion of the sheet material, generating an equation for determining two straight edges of the sheet material using detection signals, and using the two straight edges.

7. The traceless forming process of the high-strength plate of the large variable cross-section structural part according to claim 1, wherein the traceless forming process comprises the following steps: in S8, an inflatable airbag is installed inside the transportation bracket to provide joint protection to both sides of the component.

8. The traceless forming process of the high-strength plate of the large variable cross-section structural part according to claim 1, wherein the traceless forming process comprises the following steps: in S5, after the bending process of the workpiece is completed, and before and after the lifting, the lifting height of the crane is adjusted according to the height difference of the bent plate, so as to keep the balance of the workpiece on the die.

Technical Field

The invention relates to the technical field of high-strength plate production, in particular to a traceless forming process for a high-strength plate of a large variable cross-section structural member.

Background

As is well known, with the development of ocean wind power, the requirement on the hoisting capacity of a crane ship is higher and higher, that is, the crane ship needs a ship hoisting device with a larger size, and as the hoisting device is increased, the base of the crane is correspondingly increased, the base of the crane is generally circular at the upper part so as to be convenient for connecting a slewing bearing of a slewing mechanism of the whole crane, and generally square at the lower part so as to be convenient for connecting a ship body structure, and a variable-section steel structure connecting piece is designed by combining the requirements on the ship body arrangement and the deck surface.

However, the existing forming process of the sectional structural member plate has certain problems:

the existing cross-section structural member has high structural strength, complex shape, difficult molding and high precision requirement, so that the problems are difficult to solve by the common manufacturing process;

secondly, after the existing cross-section structural member is manufactured and formed by the plate, the dimension leveling comparison of the upper opening and the lower opening of the structural member is often lost, and a measuring mechanism is not used for measuring the structural member, so that the finished product yield is lower.

Disclosure of Invention

Technical problem to be solved

Aiming at the defects of the prior art, the invention provides a traceless forming process for a high-strength plate of a large variable cross-section structural member.

(II) technical scheme

In order to achieve the purpose, the invention provides the following technical scheme: the traceless forming process of the high-strength plate of the large variable cross-section structural member comprises the following steps:

s1, preparation materials: preparing a base with the size of a square bottom of 14m by 12m, an upper circular with the diameter of 14m and the height of 5.4m, preparing 4 plates and two flat sections, wherein the plates are StE690 high-strength plates, the plate thickness is 30-60 mm, and the precision is that the contour line deviation of a finished product does not exceed 5mm of a theoretical central line;

s2, designing and manufacturing a forming die: designing a proper upper die and a proper lower die by combining the molding height difference of the two ends according to the drawing requirements, simulating the molding of the material by adopting simulation software after the design is finished, and producing and manufacturing after the result is correct;

s3, manufacturing a test template: after the appearance data of the product is obtained, a corresponding sample plate is manufactured by laser, multiple sample plates are designed to check the sizes of the upper opening, the lower opening and the waist line position, and the sample plates are used for checking during the completion;

s4, scribing: marking according to a drawing, wherein in the marking process, each line of the subsequent forming precision is checked, the error is controlled within-1 mm, and the marking density depends on the size of a product and the forming difficulty;

s5, bending: in the bending process, each bending is accurately measured, the upper die is centered by using laser, and the contact line of the die is accurately pressed on the scribing position of a processed workpiece;

s6, hoisting: after the workpiece is bent, in order to prevent the deformation caused by lifting, a plurality of traveling cranes are adopted for lifting and turning over, and the workpiece is stably lifted and placed on a platform with a pre-marked forming diagram;

s7, correction and detection: 1:1 marking on a platform according to the size characteristics of upper and lower openings of a structural member, lifting a workpiece onto the platform after marking is finished, enabling the upper and lower openings of the workpiece to be basically consistent with the marking in projection, leveling the workpiece by using a level instrument, and measuring a product by using a total station after leveling is finished;

s8, transportation: the parts are irregular in shape, more stress exists in the parts, and the parts are fixed and transported by a specially-made bracket during transportation, so that deformation caused in the transportation process is prevented.

Preferably, in S2, the die is made of a high-strength alloy material, and after the die is finished, the die is dipped into fire to increase the surface hardness, and then is ground.

Preferably, in S3, the structure is divided according to the equipment drawing of the crane equipment factory, and the structure can be divided into 1-3 layers according to the size of the base.

Preferably, in S7, after the plurality of boards are manufactured and measured, the entire base can be spliced, so as to complete the task of the base.

Preferably, in S7, when an error is found in the measurement, the workpiece needs to be corrected again, and the correction is performed by using a method of continuing to adjust the bending machine or using a fire until the dimensional accuracy meeting the requirement of the drawing is achieved.

Preferably, in S5, the bending angle is determined by installing a scanner in the bending machine, the scanner emitting a beam to a straight edge of the bent portion of the plate material, and generating an equation for determining two straight edges of the plate material by using detection signals.

Preferably, in S8, an inflatable airbag is installed inside the transportation bracket to provide a joint protection for both sides of the component.

Preferably, in S5, when the bending process of the workpiece is completed, and before and after the bending process, the lifting height of the crane is adjusted according to the height difference of the bent plate, so as to keep the balance of the workpiece on the die.

(III) advantageous effects

Compared with the prior art, the invention provides a traceless forming process for the high-strength plate of the large variable cross-section structural member, which has the following beneficial effects:

firstly, the invention selects high-strength plate materials, adopts the design and manufacture of a forming die, manufactures a corresponding sample plate manufacturing inspection sample plate through laser, performs marking and bending operations on the sample plate according to a drawing, and ensures no error of the plate and high strength of the plate through the manufacturing of the sample plate die, the selection of the materials and the marking and bending operations.

Secondly, after the plate is manufactured and molded, 1:1 marking is carried out on the upper surface of the platform according to the size characteristics of the upper opening and the lower opening of the structural part, then a workpiece is leveled by using a level instrument, a product is measured by using a total station, and the yield of the finished product is improved by measuring and leveling the product.

Drawings

FIG. 1 is a schematic structural view of the present invention;

FIG. 2 is a schematic top view of the present invention;

FIG. 3 is a schematic side view of the present invention;

fig. 4 is a schematic structural diagram after molding of the present invention.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

Example one

Referring to fig. 1-4, the present invention provides a technical solution: the traceless forming process of the high-strength plate of the large variable cross-section structural member comprises the following steps:

s1, preparation materials: preparing 4 plates with the size of a square bottom of 14m by 12m, the diameter of an upper circle of 14m and the height of 5.4m, preparing two flat sections, wherein the plates are StE690 high-strength plates, the plate thickness is 30mm, and the precision is that the contour line deviation of a finished product does not exceed 5mm of a theoretical central line;

s2, designing and manufacturing a forming die: designing a proper upper die and a proper lower die by combining the molding height difference of the two ends according to the drawing requirements, simulating the molding of the material by adopting simulation software after the design is finished, and producing and manufacturing after the result is correct;

s3, manufacturing a test template: after the appearance data of the product is obtained, a corresponding sample plate is manufactured by laser, multiple sample plates are designed to check the sizes of the upper opening, the lower opening and the waist line position, and the sample plates are used for checking during the completion;

s4, scribing: marking according to a drawing, wherein in the marking process, each line of the subsequent forming precision is checked, the error is controlled within 0.8mm, and the marking density depends on the size of a product and the forming difficulty;

s5, bending: in the bending process, each bending is accurately measured, the upper die is centered by using laser, and the contact line of the die is accurately pressed on the scribing position of a processed workpiece;

s6, hoisting: after the workpiece is bent, in order to prevent the deformation caused by lifting, a plurality of traveling cranes are adopted for lifting and turning over, and the workpiece is stably lifted and placed on a platform with a pre-marked forming diagram;

s7, correction and detection: 1:1 marking on a platform according to the size characteristics of upper and lower openings of a structural member, lifting a workpiece onto the platform after marking is finished, enabling the upper and lower openings of the workpiece to be basically consistent with the marking in projection, leveling the workpiece by using a level instrument, and measuring a product by using a total station after leveling is finished;

s8, transportation: the parts are irregular in shape, more stress exists in the parts, and special brackets are adopted for fixing and transporting during transportation.

In this embodiment, specifically: in S2, the die is made of a high-strength alloy material, and after the die is finished, the die is dipped with fire to increase the surface hardness, and then ground.

In this embodiment, specifically: in S3, the structure is divided into 1 layer according to the equipment drawing of the crane factory and the size of the base.

In this embodiment, specifically: in S7, after the plurality of boards are manufactured and measured, the entire base can be spliced, thereby completing the task of the base.

In this embodiment, specifically: in S7, the measurement finds that there is an error, and the workpiece needs to be corrected again by using the method of continuing the adjustment of the bending machine until the dimensional accuracy meeting the requirements of the drawing is achieved.

In this embodiment, specifically: in S5, the bending angle is determined by installing a scanner in the bending machine, the scanner emitting a beam to a straight side of a bent portion of the sheet material, and generating an equation for determining two straight sides of the sheet material using detection signals.

In this embodiment, specifically: at S8, an inflatable airbag is installed inside the transportation bracket to provide joint protection for both sides of the component.

In this embodiment, specifically: in S5, after the bending process of the workpiece is completed, the hoisting height of the crane is adjusted according to the height difference of the bent plate before and after hoisting, so as to keep the balance of the workpiece on the die.

Example two

Referring to fig. 1-4, the present invention provides a technical solution: the traceless forming process of the high-strength plate of the large variable cross-section structural member comprises the following steps:

s1, preparation materials: preparing 4 plates with the size of a square bottom of 14m by 12m, the diameter of an upper circle of 14m and the height of 5.4m, preparing two flat sections, wherein the plates are StE690 high-strength plates with the thickness of 60mm, and the contour line deviation of the finished product does not exceed 5mm of the theoretical center line;

s2, designing and manufacturing a forming die: designing a proper upper die and a proper lower die by combining the molding height difference of the two ends according to the drawing requirements, simulating the molding of the material by adopting simulation software after the design is finished, and producing and manufacturing after the result is correct;

s3, manufacturing a test template: after the appearance data of the product is obtained, a corresponding sample plate is manufactured by laser, multiple sample plates are designed to check the sizes of the upper opening, the lower opening and the waist line position, and the sample plates are used for checking during the completion;

s4, scribing: marking according to a drawing, wherein in the marking process, each line of the subsequent forming precision is checked, the error is controlled within 1mm, and the marking density depends on the size of a product and the forming difficulty;

s5, bending: in the bending process, each bending is accurately measured, the upper die is centered by using laser, and the contact line of the die is accurately pressed on the scribing position of a processed workpiece;

s6, hoisting: after the workpiece is bent, in order to prevent the deformation caused by lifting, a plurality of traveling cranes are adopted for lifting and turning over, and the workpiece is stably lifted and placed on a platform with a pre-marked forming diagram;

s7, correction and detection: 1:1 marking on a platform according to the size characteristics of upper and lower openings of a structural member, lifting a workpiece onto the platform after marking is finished, enabling the upper and lower openings of the workpiece to be basically consistent with the marking in projection, leveling the workpiece by using a level instrument, and measuring a product by using a total station after leveling is finished;

s8, transportation: the parts are irregular in shape, more stress exists in the parts, and the parts are fixed and transported by a specially-made bracket during transportation, so that deformation caused in the transportation process is prevented.

In this embodiment, specifically: in S2, the die is made of a high-strength alloy material, and after the die is finished, the die is dipped with fire to increase the surface hardness, and then ground.

In this embodiment, specifically: in S3, the structure is divided into 3 layers according to the equipment drawing of the crane factory and the size of the base.

In this embodiment, specifically: in S7, after the plurality of boards are manufactured and measured, the entire base can be spliced, thereby completing the task of the base.

In this embodiment, specifically: in S7, errors are found in the measurement, the workpiece needs to be corrected again, and the workpiece is corrected by continuously using the firer until the dimensional accuracy meeting the requirements of the drawing is achieved.

In this embodiment, specifically: in S5, the bending angle is determined by installing a scanner in the bending machine, the scanner emitting a beam to a straight side of a bent portion of the sheet material, and generating an equation for determining two straight sides of the sheet material using detection signals.

In this embodiment, specifically: at S8, an inflatable airbag is installed inside the transportation bracket to provide joint protection for both sides of the component.

In this embodiment, specifically: in S5, after the bending process of the workpiece is completed, the hoisting height of the crane is adjusted according to the height difference of the bent plate before and after hoisting, so as to keep the balance of the workpiece on the die.

EXAMPLE III

Referring to fig. 1-4, the present invention provides a technical solution: the traceless forming process of the high-strength plate of the large variable cross-section structural member comprises the following steps:

s1, preparation materials: preparing 4 plates with the size of a square bottom of 14m by 12m, the diameter of an upper circle of 14m and the height of 5.4m, preparing two flat sections, wherein the plates are StE690 high-strength plates, the plate thickness is 40mm, and the precision is that the contour line deviation of a finished product does not exceed 5mm of a theoretical central line;

s2, designing and manufacturing a forming die: designing a proper upper die and a proper lower die by combining the molding height difference of the two ends according to the drawing requirements, simulating the molding of the material by adopting simulation software after the design is finished, and producing and manufacturing after the result is correct;

s3, manufacturing a test template: after the appearance data of the product is obtained, a corresponding sample plate is manufactured by laser, multiple sample plates are designed to check the sizes of the upper opening, the lower opening and the waist line position, and the sample plates are used for checking during the completion;

s4, scribing: marking according to a drawing, wherein in the marking process, each line of the subsequent forming precision is checked, the error is controlled within 0.5mm, and the marking density depends on the size of a product and the forming difficulty;

s5, bending: in the bending process, each bending is accurately measured, the upper die is centered by using laser, and the contact line of the die is accurately pressed on the scribing position of a processed workpiece;

s6, hoisting: after the workpiece is bent, in order to prevent the deformation caused by lifting, a plurality of traveling cranes are adopted for lifting and turning over, and the workpiece is stably lifted and placed on a platform with a pre-marked forming diagram;

s7, correction and detection: 1:1 marking on a platform according to the size characteristics of upper and lower openings of a structural member, lifting a workpiece onto the platform after marking is finished, enabling the upper and lower openings of the workpiece to be basically consistent with the marking in projection, leveling the workpiece by using a level instrument, and measuring a product by using a total station after leveling is finished;

s8, transportation: the parts are irregular in shape, more stress exists in the parts, and the parts are fixed and transported by a specially-made bracket during transportation, so that deformation caused in the transportation process is prevented.

In this embodiment, specifically: in S2, the die is made of a high-strength alloy material, and after the die is finished, the die is dipped with fire to increase the surface hardness, and then ground.

In this embodiment, specifically: in S3, the structure is divided into 2 layers according to the equipment drawing of the crane factory and the size of the base.

In this embodiment, specifically: in S7, after the plurality of boards are manufactured and measured, the entire base can be spliced, thereby completing the task of the base.

In this embodiment, specifically: in S7, the measurement finds that there is an error, and the workpiece needs to be corrected again by using the method of continuing the adjustment of the bending machine until the dimensional accuracy meeting the requirements of the drawing is achieved.

In this embodiment, specifically: in S5, the bending angle is determined by installing a scanner in the bending machine, the scanner emitting a beam to a straight side of a bent portion of the sheet material, and generating an equation for determining two straight sides of the sheet material using detection signals.

In this embodiment, specifically: at S8, an inflatable airbag is installed inside the transportation bracket to provide joint protection for both sides of the component.

In this embodiment, specifically: in S5, after the bending process of the workpiece is completed, the hoisting height of the crane is adjusted according to the height difference of the bent plate before and after hoisting, so as to keep the balance of the workpiece on the die.

Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.