装载机挖掘机动臂焊接应力焊接变形控制研究及应用
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摘要
本文以具体研究ZL50C装载机动臂组合、CLG200-3动臂箱体焊接生产现场和使用过程中产生局部裂纹和变形的机理,通过测试动臂组合和动臂箱体的焊接残余应力应变,分析动臂焊接变形及开裂产生的原因,制定生产现场控制焊接应力焊接变形的措施,并具体应用于生产现场以控制装载机ZL50C的动臂焊接变形达到产品的技术要求。
本文通过理论分析,指出装载机和挖掘机产生焊接应力应变的本质,并且制定出控制装载机动臂组合焊后变形、挖掘机动臂箱体焊后焊接应力的总体方案措施,为控制装载机动臂组合焊接变形和挖掘机动臂焊接裂纹的焊接工艺奠定基础。
生产现场对装载机ZL50C挖掘机CLG200-3动臂焊接残余应变应力进行测试,并且对所测试的装载机、挖掘机焊接应力的分布及应力变化趋势进行的分析,对生产现场控制装载机、挖掘机焊接应力变形工艺措施的具体制定有重要的指导意义。
针对装载机动臂组合焊接生产中动臂板焊后所存在的角变形和扭曲变形,从理论和施焊现场工艺方面分析了动臂组合产生变形的原因,并通过对动臂组合焊接方法的正确选择、焊接顺序和焊接规范的优化设计,有效地解决了装载机动臂组合焊接变形的问题。
根据生产现场对装载机动臂组合、挖掘机动臂箱体焊接应变应力的测试结果,本文得到一系列的结论,并且对装载机动臂组合的产品范例进行实验,实验结果表明:采用本文设计的分段退焊或分段对称焊的生产工艺可以明显减小装载机动臂组合的焊接变形,无须焊后校形即可达到产品设计的要求。
Based on the experimental study of the welding deformation and welding crack appearing in the course of welding in active arms of loading machine ZL50C and digging machine CLG200-3, projects are settled to control welding deformation and welding stress by analyzing reasons of welding deformations, welding cracks and testing welding residual stress. In addition ,the projects are used for welding active arms of loading machine ZL50C to control its welding deformation.
The essence of welding deformation and welding stress appearing in the course of welding in active arms of loading machine and digging machine is analyzed in theory ,we established a whole project that’s used to control welding deformation of loading machine and welding stress of digging machine, which have theoretically directive sense in practical course of production.
Welding stress is tested in local workshops ,furthermore, the distributing of welding stress and the changing trend of welding stress are analyzed, which are important to control welding deformation and welding stress in the course of practical production.
Aiming at the angle and distort deformation appearing in the course of welding in loading machine active arms combinations,the reasons of the deformation is analyzed in theory and local producing techniqes ,then the deformation is successfully resolved by means of selecting correct welding methods , welding orders and optimizing welding criterion design.
According to the testing result of welding deformation and welding stress of loading machine and digging machine, we got a series of conclusions,one of which shows that backstep welding can greatly reduce welding deformation of loading machine compared with direct welding method, and active arms can satisfy the request of production design by means of backstep welding without rectification.
本文通过理论分析,指出装载机和挖掘机产生焊接应力应变的本质,并且制定出控制装载机动臂组合焊后变形、挖掘机动臂箱体焊后焊接应力的总体方案措施,为控制装载机动臂组合焊接变形和挖掘机动臂焊接裂纹的焊接工艺奠定基础。
生产现场对装载机ZL50C挖掘机CLG200-3动臂焊接残余应变应力进行测试,并且对所测试的装载机、挖掘机焊接应力的分布及应力变化趋势进行的分析,对生产现场控制装载机、挖掘机焊接应力变形工艺措施的具体制定有重要的指导意义。
针对装载机动臂组合焊接生产中动臂板焊后所存在的角变形和扭曲变形,从理论和施焊现场工艺方面分析了动臂组合产生变形的原因,并通过对动臂组合焊接方法的正确选择、焊接顺序和焊接规范的优化设计,有效地解决了装载机动臂组合焊接变形的问题。
根据生产现场对装载机动臂组合、挖掘机动臂箱体焊接应变应力的测试结果,本文得到一系列的结论,并且对装载机动臂组合的产品范例进行实验,实验结果表明:采用本文设计的分段退焊或分段对称焊的生产工艺可以明显减小装载机动臂组合的焊接变形,无须焊后校形即可达到产品设计的要求。
Based on the experimental study of the welding deformation and welding crack appearing in the course of welding in active arms of loading machine ZL50C and digging machine CLG200-3, projects are settled to control welding deformation and welding stress by analyzing reasons of welding deformations, welding cracks and testing welding residual stress. In addition ,the projects are used for welding active arms of loading machine ZL50C to control its welding deformation.
The essence of welding deformation and welding stress appearing in the course of welding in active arms of loading machine and digging machine is analyzed in theory ,we established a whole project that’s used to control welding deformation of loading machine and welding stress of digging machine, which have theoretically directive sense in practical course of production.
Welding stress is tested in local workshops ,furthermore, the distributing of welding stress and the changing trend of welding stress are analyzed, which are important to control welding deformation and welding stress in the course of practical production.
Aiming at the angle and distort deformation appearing in the course of welding in loading machine active arms combinations,the reasons of the deformation is analyzed in theory and local producing techniqes ,then the deformation is successfully resolved by means of selecting correct welding methods , welding orders and optimizing welding criterion design.
According to the testing result of welding deformation and welding stress of loading machine and digging machine, we got a series of conclusions,one of which shows that backstep welding can greatly reduce welding deformation of loading machine compared with direct welding method, and active arms can satisfy the request of production design by means of backstep welding without rectification.
引文
张文钺. 知识经济时代材料加工(焊接)和先进制造技术的地位与发展[J]. 焊接. 2001(6), 6-10
何孚德. 焊接与连接工程学导论. 上海交通大学出版社. 1998.12. 1-8
Hal stacey. In the beginning...[J]. Welding journal. 1993. 45-47
邱莜娟. 焊接结构在工程应用种的质量保证[J]. 机械. VOL.27. 2000
V.A.Geikin, B.E.Karasev and A.V.Logunov(Russia). Trends in the application of welding to aircraft engineer construction[J]. Welding in the world. 1999. 411-412
(俄)奥凯尔勃洛姆. 雷原译. 焊接变形与应力. 机械工业出版社. 1958
田锡唐. 焊接结构. 机械工业出版社. 1981. 1-77
天津大学编著. 焊接结果与生产. 机械工业出版社. 1997
稻垣道夫, 刚铁. 焊接生产技术的地位与发展(2)[J]. 焊接. 1999(2)
段金钟. 我国工程机械焊接业的发展趋势──低成本自动焊[J]. 工程机械. 2000(3)
J.Puchaicela. Control of distortion of welding steel structures[J]. Welding journal. 1998. 49-52
Prof.Dr.Jozsef FARKAS and Assoc.Prof.Dr.Karoly. The effect of low cost technologies in the desigh of welded structures. Welding In The World. 1994
陈伯蠡. 金属焊接性基础. 机械工业出版社.1982
Bob Irving. Times are though for basic welding research. Welding journal. 1997. 43-44
王劲松. 从bauma98看挖掘机和装载机的技术发展[J]. 1998(6)
柏红专. 国外轮式装载机的发展趋势[J]. 建筑机械. 1994(1)
赵瑛. 国外轮式装载机的发展现状与趋势[J]. 工程机械. 1995(11)
田志成. 预测我国装载机行业发展趋势[J]. 工程机械与维修. 1998(11)
周明龙. 国内外水陆两用液压挖掘机发展概况[J]. 工程机械与维修. 1996(6)
王国彪. 国外大型矿用挖掘机的现状与发展[J]. 矿山机械. 1999(11)
陈正利. 我国液压挖掘机发展的几个重要阶段及其前景展望[J]. 建筑机械. 1999(1)
董立队. 装载机产品的发展特点. 工程机械与维修. 2002(5)
世界采矿快报. 矿用挖掘机发展方向. 2000(7)
马鹏飞, 田奇. 挖掘机的发展方向[J]. 筑路机械与施工机械化. 2000(6)
赵昱东. 引进先进技术 加速液压挖掘机发展[J]. 建筑机械化. 1997(3)
朱建新,邹湘伏,黄志雄. 谈国产液压挖掘机未来的发展趋势[J]. 凿岩机械气动工具. 2003(3)
张文钺. 金属熔焊原理与工艺(上册). 机械工业出版社. 1980
(德)D.拉达伊. 焊接热效应、残余应力、变形. 机械工业出版社. 1997. 136-300
周振丰,张文钺.焊接冶金与金属焊接性. 机械工业出版社. 1987
徐光宏,陈鸿鹄,徐光远,尹 龙. 大型焊接构件变形与对策[J]. 煤矿机械. 2002(10)
徐初雄. 焊接工艺500问. 机械工业出版社. 1997
徐初雄. 焊接技术问答. 机械工业出版社. 2001
蔡杰,王元良. 小盲孔法和磁性法测残余应力比较. 焊接十委年会论文集. 1998
An investigation of vibration stress relief in steel[J]. Welding journal. 1968(9)
陆才善. 残余应力测试—小孔释放法. 西安:西安交通大学出版社. 1991
霍立兴. 焊接结构工程强度. 机械工业出版社. 1995.4
尹士科等. 焊接接头性能调控与应用(碳钢与低合金钢). 兵器工业出版社. 1993.9
中国机械工程学会焊接学会. 焊接手册(第三卷). 北京:机械工业出版社. 1992. 73
龙昕,汪建华. 温差法在焊接残余应力和变形控制中的应用[J]. 制造安装. Vol17. 2000
何孚德. 焊接与连接工程学导论. 上海交通大学出版社. 1998.12. 1-8
Hal stacey. In the beginning...[J]. Welding journal. 1993. 45-47
邱莜娟. 焊接结构在工程应用种的质量保证[J]. 机械. VOL.27. 2000
V.A.Geikin, B.E.Karasev and A.V.Logunov(Russia). Trends in the application of welding to aircraft engineer construction[J]. Welding in the world. 1999. 411-412
(俄)奥凯尔勃洛姆. 雷原译. 焊接变形与应力. 机械工业出版社. 1958
田锡唐. 焊接结构. 机械工业出版社. 1981. 1-77
天津大学编著. 焊接结果与生产. 机械工业出版社. 1997
稻垣道夫, 刚铁. 焊接生产技术的地位与发展(2)[J]. 焊接. 1999(2)
段金钟. 我国工程机械焊接业的发展趋势──低成本自动焊[J]. 工程机械. 2000(3)
J.Puchaicela. Control of distortion of welding steel structures[J]. Welding journal. 1998. 49-52
Prof.Dr.Jozsef FARKAS and Assoc.Prof.Dr.Karoly. The effect of low cost technologies in the desigh of welded structures. Welding In The World. 1994
陈伯蠡. 金属焊接性基础. 机械工业出版社.1982
Bob Irving. Times are though for basic welding research. Welding journal. 1997. 43-44
王劲松. 从bauma98看挖掘机和装载机的技术发展[J]. 1998(6)
柏红专. 国外轮式装载机的发展趋势[J]. 建筑机械. 1994(1)
赵瑛. 国外轮式装载机的发展现状与趋势[J]. 工程机械. 1995(11)
田志成. 预测我国装载机行业发展趋势[J]. 工程机械与维修. 1998(11)
周明龙. 国内外水陆两用液压挖掘机发展概况[J]. 工程机械与维修. 1996(6)
王国彪. 国外大型矿用挖掘机的现状与发展[J]. 矿山机械. 1999(11)
陈正利. 我国液压挖掘机发展的几个重要阶段及其前景展望[J]. 建筑机械. 1999(1)
董立队. 装载机产品的发展特点. 工程机械与维修. 2002(5)
世界采矿快报. 矿用挖掘机发展方向. 2000(7)
马鹏飞, 田奇. 挖掘机的发展方向[J]. 筑路机械与施工机械化. 2000(6)
赵昱东. 引进先进技术 加速液压挖掘机发展[J]. 建筑机械化. 1997(3)
朱建新,邹湘伏,黄志雄. 谈国产液压挖掘机未来的发展趋势[J]. 凿岩机械气动工具. 2003(3)
张文钺. 金属熔焊原理与工艺(上册). 机械工业出版社. 1980
(德)D.拉达伊. 焊接热效应、残余应力、变形. 机械工业出版社. 1997. 136-300
周振丰,张文钺.焊接冶金与金属焊接性. 机械工业出版社. 1987
徐光宏,陈鸿鹄,徐光远,尹 龙. 大型焊接构件变形与对策[J]. 煤矿机械. 2002(10)
徐初雄. 焊接工艺500问. 机械工业出版社. 1997
徐初雄. 焊接技术问答. 机械工业出版社. 2001
蔡杰,王元良. 小盲孔法和磁性法测残余应力比较. 焊接十委年会论文集. 1998
An investigation of vibration stress relief in steel[J]. Welding journal. 1968(9)
陆才善. 残余应力测试—小孔释放法. 西安:西安交通大学出版社. 1991
霍立兴. 焊接结构工程强度. 机械工业出版社. 1995.4
尹士科等. 焊接接头性能调控与应用(碳钢与低合金钢). 兵器工业出版社. 1993.9
中国机械工程学会焊接学会. 焊接手册(第三卷). 北京:机械工业出版社. 1992. 73
龙昕,汪建华. 温差法在焊接残余应力和变形控制中的应用[J]. 制造安装. Vol17. 2000