CN102935552B - Flash welding forming method of constructional steel thin-wall ring member - Google Patents
Flash welding forming method of constructional steel thin-wall ring member Download PDFInfo
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- CN102935552B CN102935552B CN201210479207.2A CN201210479207A CN102935552B CN 102935552 B CN102935552 B CN 102935552B CN 201210479207 A CN201210479207 A CN 201210479207A CN 102935552 B CN102935552 B CN 102935552B
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Abstract
The invention discloses a flash welding forming method of a constructional steel thin-wall ring member, which comprises the steps of: loading a D type ring blank with an opening in a welder, starting the welder to close the opening of the preheated ring blank, applying a 7-18V voltage between two poles of the welder to ensure that the left end face and the right end face of the opening of the ring blank are heated and molten through a flash current with the current density of 15A/mm<2>-220A/mm<2> to form a lintel, exploding to form a flash, wherein the flash burning loss speed of the ring blank is 3.6mm-7.2mm/s; driving the right end face of the ring blank to make an accelerated feeding movement towards the left end face at an initial speed of 2.5mm/s-4.0mm/s and an acceleration of 1.0mm/s<2>-2.0mm/s<2> so as to ensure that the distance between the left end face and the right end face is not more than 7mm; and after the flash is completed, driving a right straight side of the ring blank to move at a high speed towards a left straight side of the ring blank to ensure that the left end face and the right end face collide with each other under the action of an upsetting force of 9kN-15kN to form the flash welding thin-wall ring member, and keeping the pressure for 10s-30s under the action of the upsetting force. The method can ensure that the flash process is continuously and stably carried out, thereby improving the weld quality.
Description
Technical field
The present invention relates to a kind of welding method, particularly relate to the flash welding manufacturing process of constructional steel thin-wall ring.
Background technology
Along with the industries such as Aeronautics and Astronautics, boats and ships, gas turbine, wind energy, nuclear energy and bearing are to the increase of ring demand, the ring adopting traditional milling method to be shaped is because machine-finish allowance is large, stock utilization is low, not only waste a large amount of materials, but also the cost of ring is remained high.And adopting the ring of Flash Butt Welding explained hereafter, it is few that machine adds surplus, and stock utilization is high, and cost also reduces thereupon greatly, is conducive to ring is shaped towards Precision Forming Technology future development.
Disclosed in 3 days November in 1999, Chinese invention patent description CN 1233548A discloses a kind of automobile, motorcycle aluminium alloy wheel Flash Butt Welding technique, the technological process that this technique adopts for wheel is: pre-treatment → welding condition setting → clamping workpiece → flash of light → upset → pressurize → release clamp → finishing, solve the welding forming technical problem of aluminum-alloy wheel ring, described wheel is thin-walled ring.But, in the process adopting flash-butt welding process welding thin-walled ring such as constructional steel thin-wall ring, if the distance between the both ends of the surface of ring base commissure control bad will cause flash of light stop, thus impact welding continue carry out and weldquality, weldment also can be caused time serious to scrap.
Summary of the invention
When the technical problem to be solved in the present invention is to provide a kind of welding commissure both ends of the surface between by maintaining a certain distance the flash welding manufacturing process realizing constructional steel thin-wall ring, the method can make ring carry out constantly in flash welding process, thus improves welding quality.
For solving the problems of the technologies described above, the flash welding manufacturing process of constructional steel thin-wall ring of the present invention, its technical scheme comprises the following steps:
It is the flash butt welder of 1000KVA that the structural steel D shape ring base of band opening is put into power, and the straight flange of its opening part arranged on left and right sides is clamped with the clamping force of 5KN ~ 8KN by the electroded clamping device of the arranged on left and right sides of described welding machine respectively;
The voltage of 7 ~ 18V is applied between the arranged on left and right sides electrode of described flash butt welder, starting mobile platen drives clamping device left and right on support in right side to move in parallel, the left and right both ends of the surface of D type ring base opening part are contacted rapidly, separate rapidly again, form interrupted flash of light and preheating is carried out to left and right both ends of the surface, described left and right both ends of the surface contact and separately after 45 ~ 75 times, each conduction time 0.02s, described left and right both ends of the surface are heated to 1180 ± 20 DEG C respectively;
The right side straight flange starting described welding machine driving D shape ring base moves towards straight flange direction, left side and the opening of described ring base is closed, apply the weldingvoltage of 7V ~ 18V at two inter-stages of described welding machine, make the fine contact point on the left side of described ring base opening part and right side be 15A/mm by current density
2~ 220A/mm
2exothermic melting after flashing current, formation connects the liquid lintel of two ends metal and outwards sprays formation flash of light at a high speed after there is explosion, and the flash of light scaling loss speed between described left and right both ends of the surface is 3.6mm/s ~ 7.2mm/s; Then the right side of described ring base opening part is driven towards left side with the initial velocity of 2.5mm/s ~ 4.0mm/s and 1.0mm/s
2~ 2.0mm/s
2acceleration do accelerate feed motion, constantly liquid lintel and continuous explosion is formed between described left side and right side, distance≤7mm between described left side and right side, flash of light process lasts carries out, until reach predetermined flash loss 15mm ~ 25mm after the flash time of 3s ~ 5s, flash of light process terminates, and by motlten metal that one deck very thin is covered between the left side after being burnt and right side by flash of light;
The right side straight flange of D type ring base is driven to move in straight flange direction to the left with the speed of 80mm/s ~ 120mm/s high speed, make described burnt by flash of light after the upset force effect at 9KN ~ 15KN of right side and left side under impinge upon together with, described ring base is configured as flash welding thin-walled ring by upset;
Described thin-walled ring takes apart from welding machine after pressurize 10s ~ 30s under the effect of upset force.
In flash of light process, the right side of described D type ring base opening part is as follows to the initial feed speed of left side, relation between flash of light acceleration and flash of light scaling loss speed:
V
1---flash of light scaling loss speed (mm/s);
V
0---in flash of light process, the right side of D type ring base opening part is to the initial velocity (mm/s) during the feeding of left side;
A---flash of light acceleration (mm/s
2);
Described structural steel is preferably 38CrA alloy.
The axial cross section size of described ring is 65mm × 30mm to the maximum.
Compared with prior art, beneficial effect of the present invention is as follows:
The flash welding manufacturing process of constructional steel thin-wall ring of the present invention, distance in welding process between the left side of D type ring base opening part and right side must be less than or equal to certain value, guarantee contact point is constantly melted and is gone out by flash of light explosion, and this is the necessary condition that motlten metal forms lintel.Adopt power to be the flash butt welder of 1000KVA for the present invention, under given technological parameter condition, this certain value equals 7mm, therefore, distance between described left side and right side is necessary≤7mm, and guarantee flash of light process lasts carries out, and improves welding quality; If the distance between described left side and right side is greater than 7mm, motlten metal just cannot form lintel, causes flash of light process to occur open circuit conditions thus causes flash of light to stop, affect welding progress and likely cause weldment to scrap.
In flash of light process, because the right side of D type ring base opening part is to the feed speed V of left side
2increase gradually along with the time, and the scaling loss speed V that glistens
1constant under given technological parameter condition, therefore, flash of light beginning initial stage V
2<V
1, the spacing between described left side and right side constantly increases, the spacing=7mm between described left side and right side, reaches the critical value that motlten metal forms lintel, V
2=V
1; If now continue at V
2<V
1condition under continue flash of light, will the spacing >7mm between described left side and right side be caused, just cannot form lintel between described left side and right side and produce open circuit, flash of light termination.Therefore, after the spacing between described left side and right side reaches 7mm, must at V
2>V
1condition under continue flash of light, the spacing between described left side and right side just can be made progressively to reduce, flash of light process is continued and stably carries out, until the contact surface that flash of light process terminates described left and right both ends of the surface is covered by the motlten metal that one deck is very thin.
If described right side is V to the initial velocity of left side feeding
0, then have:
Formula is 1.: V
2=V
0+ at;
The distance fallen due to described left and right end face flash of light scaling loss is V
1t, described right side to the feeding distance of left side is
make the distance≤7mm between described left side and right side, then have:
Formula is 2.:
Spacing=7mm between described left side and right side, reaches the critical value that motlten metal forms lintel, then has:
Formula is 3.: V
2=V
1
By above-mentioned formula 1. ~ 3. formula can derive:
Therefore, in flash of light process, if the right side of D type ring base opening part is satisfied with flash of light scaling loss speed towards the initial feed speed flash of light acceleration of left side
described ring just can be made to carry out sustainedly and stably in flash welding process, obtain weld part of good performance.
Take the trade mark as the constructional steel thin-wall ring of 38CrA be example, after heat treatment detect the room temperature tensile properties of this alloy thin-wall ring weld part, its tensile strength is 825MPa (being greater than the 796.5MPa of design instructions for use), and elongation after fracture was 7% (being greater than 6% of design instructions for use).
Accompanying drawing explanation
Below in conjunction with the drawings and specific embodiments, the present invention is described in further detail.
Fig. 1 is the schematic diagram that flash butt welder put into by D type ring base.
Fig. 2 is the flash stage schematic diagram of D type ring base.
Fig. 3 is the schematic diagram after the flash of light of D type ring base opening part terminates.
Fig. 4 is the upset schematic diagram of D type ring base opening part.
Fig. 5 is the thin-walled ring schematic diagram of welding forming.
Detailed description of the invention
The flash welding manufacturing process implementing constructional steel thin-wall ring of the present invention needs to provide the equipment such as flash butt welder, manipulator.The structural steel being 38CrA for China's material trademark below describes the detailed description of the invention of the method in detail:
The main chemical elements content (percentage by weight) of this alloy is: C content 0.34% ~ 0.42%, containing Mn amount 0.50% ~ 0.80%, si content 0.17% ~ 0.37%, containing S amount≤0.015%, P content≤0.025%, containing Cr amount 0.08% ~ 1.10%, ni content≤0.40%, containing Cu amount≤0.25, surplus is Fe.
The flash welding shaping process step of this alloy thin-wall ring is as follows:
Step 1: installation.As shown in Figure 1, it is the flash butt welder of 1000KVA that the 38CrA alloy D shape ring base of band opening is put into power, described D shape ring base is made up of left side straight flange 101, right side straight flange 102 and arc-shaped side 103, the side corresponding to left side straight flange 101 at its opening 110 place has left side 111, and the side corresponding to right side straight flange 102 has right side 112.During installation, the left side straight flange 101 of described D type ring base is put in the left side clamping device 10 of flash butt welder, by the upper clamp 11 of left side clamping device 10 and lower clamp 12 (electrode) respectively from straight flange 101 on the left of the upper and lower face clamping of left side straight flange 101, clamping force is 5KN ~ 8KN; The right side straight flange 102 of described D type ring base is put in the right side clamping device 20 of flash butt welder, by the upper clamp 21 of right side clamping device 20 and lower clamp 22 (electrode) respectively from straight flange 102 on the right side of the upper and lower face clamping of right side straight flange 102, clamping force is 5KN ~ 8KN, and the upper and lower end face of left side straight flange 101 and right side straight flange 102 and front/rear end are alignd respectively.Described left side clamping device 10 is arranged in the fixed platen 30 of flash butt welder, right side clamping device 20 is arranged on the mobile platen 40 of flash butt welder, fixed platen 30 and mobile platen 40 are arranged on the support of flash butt welder, and mobile platen 40 can drive right side clamping device 20 to move in parallel back and forth towards fixed platen 30 direction on support and the opening 110 of D type ring base opened or closes.
Step 2: preheating.Under the left side of flash butt welder, clamp 12 (electrode) and clamp 22 (electrode) two inter-stage under right side apply the voltage of 7 ~ 18V, starting mobile platen 40 drives clamping device 20 left and right on support in right side to move in parallel the left side 111 at opening 110 place of D type ring base is contacted rapidly with right side 112, separate rapidly again, form interrupted flash of light and preheating is carried out to left side 111 and right side 112, described opening 110 is closed and separately after 45 ~ 75 times, each conduction time 0.02s, described left side 111 is heated to 1180 ± 20 DEG C respectively with right side 112.
Step 3: flash of light.As shown in Figure 2, start mobile platen 40 and drive right side clamping device 20 to move towards fixed platen direction on support, make the left side 111 at opening 110 place of D type ring base contact after-opening 110 with right side 112 and be in closure state; Apply the weldingvoltage of 7V ~ 18V at two inter-stages of flash butt welder, described left side 111 is 15A/mm with the fine contact point on right side 112 owing to there being current density
2~ 220A/mm
2flashing current is by forming resistance and generating heat, the metal of these contact points is melted very soon, form the liquid " lintel " connecting two ends metal, these liquid " lintel " explosion under electricity, heat, power acting in conjunction, outwards spray at a high speed and form flash of light, the flash of light scaling loss speed 3.6mm/s ~ 7.2mm/s between described left and right both ends of the surface; Afterwards mobile platen 40 move towards fixed platen direction make the right side 112 at D type ring base opening 110 place to left side 111 as initial velocity be 2.5mm/s ~ 4.0mm/s, acceleration is 1.0mm/s
2~ 2.0mm/s
2acceleration feed motion, " lintel " and continuous explosion is constantly formed between described left side 111 and right side 112, distance between described left side 111 and right side 112 remains≤7mm, flash of light process lasts carries out, until reach predetermined flash loss 15mm ~ 25mm after the flash time of 3s ~ 5s, flash of light process terminates, as shown in Figure 3, left side 111' after being burnt by flash of light and the both ends of the surface contact surface of right side 112' are covered by the motlten metal that one deck is very thin, both ends of the surface contact surface temperature reaches the fusing point of metal, and tends towards stability evenly.
In flash of light process, for keeping flash of light process can continue and stably carry out, the right side 112 at D type ring base opening 110 place should be mated with flash of light scaling loss speed mutually to the initial feed speed of left side 111, the acceleration that glistens, that is:
V
1---flash of light scaling loss speed (mm/s);
V
0---in flash of light process, the right side of D type ring base opening part is to the initial velocity (mm/s) during the feeding of left side;
A---flash of light acceleration (mm/s
2);
Power due to flash butt welder is certain value, and after having set welding parameter, in flash of light process, flash butt welder is also certain value to the energy that welding end surface applies, and therefore, when given material, flash of light scaling loss speed and flash of light acceleration are also certain values.
Step 4: upset.As shown in Figure 4, after flash of light terminates, make mobile platen 40 drive right side clamping device 20 on support towards fixed platen direction with the speed high-speed mobile of 80mm/s ~ 120mm/s, together with impinging upon under the upset force F effect at 9KN ~ 15KN of left side 111' after D type ring base is burnt by flash of light and right side 112' both ends of the surface, motlten metal between described both ends of the surface and metal oxide are all arrived surface of the work by exclusion, left side 111' and right side 112' two contact surface produce plastic deformation and make close contact between metal on two end faces and metal, D type ring base is configured as flash welding thin-walled ring 200 as shown in Figure 5 by upset, described thin-walled ring 200 has weld part 201.
Step 5: pressurize.The thin-walled ring 200 of welding forming is kept 10s ~ 30s under the effect of upset force, just can take apart from flash butt welder after weld seam fully combines.
Adopt the 38CrA constructional steel thin-wall ring of said method welding forming, its axial cross section size is 65mm × 30mm to the maximum, and wherein, 65mm refers to ring height vertically, and 30mm refers to ring wall thickness radially.
Claims (4)
1. a flash welding manufacturing process for constructional steel thin-wall ring, is characterized in that, comprise the following steps:
It is the flash butt welder of 1000KVA that the structural steel D shape ring base of band opening is put into power, and the straight flange of its opening part arranged on left and right sides is clamped with the clamping force of 5KN ~ 8KN by the electroded clamping device of the arranged on left and right sides of described welding machine respectively;
The voltage of 7 ~ 18V is applied between the arranged on left and right sides electrode of described flash butt welder, starting mobile platen drives clamping device left and right on support in right side to move in parallel, the left and right both ends of the surface of D type ring base opening part are contacted rapidly, separate rapidly again, form interrupted flash of light and preheating is carried out to left and right both ends of the surface, described left and right both ends of the surface contact and separately after 45 ~ 75 times, each conduction time 0.02s, described left and right both ends of the surface are heated to 1180 ± 20 DEG C respectively;
The right side straight flange starting described welding machine driving D shape ring base moves towards straight flange direction, left side and the opening of described ring base is closed, apply the weldingvoltage of 7V ~ 18V at two interpolars of described welding machine, make the fine contact point on the left side of described ring base opening part and right side be 15A/mm by current density
2~ 220A/mm
2exothermic melting after flashing current, formation connects the liquid lintel of two ends metal and outwards sprays formation flash of light at a high speed after there is explosion, and the flash of light scaling loss speed between described left and right both ends of the surface is 3.6mm/s ~ 7.2mm/s; Then the right side of described ring base opening part is driven towards left side with the initial velocity of 2.5mm/s ~ 4.0mm/s and 1.0mm/s
2~ 2.0mm/s
2acceleration do accelerate feed motion, constantly liquid lintel and continuous explosion is formed between described left side and right side, distance≤7mm between described left side and right side, flash of light process lasts carries out, until reach predetermined flash loss 15mm ~ 25mm after the flash time of 3s ~ 5s, flash of light process terminates, and by motlten metal that one deck very thin is covered between the left side after being burnt and right side by flash of light;
The right side straight flange of D type ring base is driven to move in straight flange direction to the left with the speed of 80mm/s ~ 120mm/s high speed, make described burnt by flash of light after the upset force effect at 9KN ~ 15KN of right side and left side under impinge upon together with, described ring base is configured as flash welding thin-walled ring by upset;
Described thin-walled ring takes apart from welding machine after pressurize 10s ~ 30s under the effect of upset force.
2. the flash welding manufacturing process of constructional steel thin-wall ring according to claim 1, is characterized in that, described flash of light scaling loss speed meets the following conditions:
in formula:
V
1---flash of light scaling loss speed (mm/s);
V
0---in flash of light process, the right side of D type ring base opening part is to the initial velocity (mm/s) during the feeding of left side;
A---flash of light acceleration (mm/s
2).
3. the flash welding manufacturing process of constructional steel thin-wall ring according to claim 1, is characterized in that: described structural steel is 38CrA.
4. the flash welding manufacturing process of the constructional steel thin-wall ring according to any one of claims 1 to 3, is characterized in that: the axial cross section size of described ring is maximum is 65mm × 30mm.
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Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN104625376B (en) * | 2014-12-15 | 2016-08-24 | 贵州安大航空锻造有限责任公司 | The flash welding manufacturing process of aluminium alloy heavy in section ring |
| CN104607781B (en) * | 2014-12-15 | 2016-08-24 | 贵州安大航空锻造有限责任公司 | The flash welding manufacturing process of rustless steel heavy in section ring |
| CN104625372B (en) * | 2014-12-15 | 2016-08-24 | 贵州安大航空锻造有限责任公司 | The flash welding manufacturing process of structural steel heavy in section ring |
| CN105880817A (en) * | 2016-05-30 | 2016-08-24 | 江苏亚星锚链股份有限公司 | Flash welding technology for R6 level mooring cable ordinary ring |
| CN107891219A (en) * | 2017-11-10 | 2018-04-10 | 江苏亚星锚链股份有限公司 | A kind of Flash Butt Welding technique of the low magnetic anchor chain of high intensity |
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| DE3706316C2 (en) * | 1987-02-27 | 1994-07-21 | Stahlberg Roensch Gmbh & Co Kg | Process for flash butt welding of parts to be butted together |
| CN1233548A (en) * | 1999-04-02 | 1999-11-03 | 上海康适达轮圈有限公司 | Flash butt welding technology for aluminium alloy wheel rim of automobile and motor cycle |
| CN102500899A (en) * | 2011-11-02 | 2012-06-20 | Bpw(梅州）车轴有限公司 | Method for producing axle beam by using preheated flash butt welding |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS55139186A (en) * | 1979-04-16 | 1980-10-30 | Toyota Motor Corp | Annular worked body and its production |
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2012
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| DE3706316C2 (en) * | 1987-02-27 | 1994-07-21 | Stahlberg Roensch Gmbh & Co Kg | Process for flash butt welding of parts to be butted together |
| CN1233548A (en) * | 1999-04-02 | 1999-11-03 | 上海康适达轮圈有限公司 | Flash butt welding technology for aluminium alloy wheel rim of automobile and motor cycle |
| CN102500899A (en) * | 2011-11-02 | 2012-06-20 | Bpw(梅州）车轴有限公司 | Method for producing axle beam by using preheated flash butt welding |
Non-Patent Citations (1)
| Title |
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| 浅析铝合金轮辋闪光对焊技术;夏良江;《电焊机》;20000428;第30卷(第4期);第3页左栏第1段至第6页右栏第2段 * |
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