水輪機(jī)焊接部件火焰矯形的討論(中英文).doc

/ / 水輪機(jī)焊接部件火焰矯形的討論（中英文）摘要:本文根據(jù)多年經(jīng)驗(yàn),結(jié)合國內(nèi)外機(jī)組相關(guān)資料,闡述水輪機(jī)主要焊接部件結(jié)構(gòu)變形的主要種類,介紹焊接變形的火焰矯形的施工方法。Abstract: this paper based on years of experience, combined with domestic and foreign units related information, this turbine main welding parts structure deformation of the main types, introduces construction method of welding deformation of flame straightening.關(guān)鍵詞:水輪機(jī);火焰矯形;焊接變形Key words: hydraulic turbine; Flame straightening; Welding deformation目前,大型水輪機(jī)部件已經(jīng)大量的采用焊接結(jié)構(gòu)。而水輪機(jī)主要焊接部件是由座環(huán)、頂蓋、底環(huán)等部件組成。這些構(gòu)件在制作過程中都存在焊接變形問題,如果焊接變形不予以矯正,則不僅影響結(jié)構(gòu)整體安裝,還會(huì)降低工程的安全可靠性。At present, the large turbine parts have a lot of welding structure. And turbine main welding parts consists of seat ring, the top and bottom ring parts. These artifacts welding deformation problems in the production process, if the welding deformation is not corrected, will not only affect the structure of the overall installation, would also reduce the safety and reliability of engineering.焊接水輪機(jī)部件產(chǎn)生的變形超過技術(shù)設(shè)計(jì)允許變形范圍,應(yīng)設(shè)法進(jìn)行矯正,使其達(dá)到符合產(chǎn)品質(zhì)量要求。實(shí)踐證明,多數(shù)變形的構(gòu)件是可以矯正的。矯正的方法都是設(shè)法造成新的變形來達(dá)到抵消已經(jīng)發(fā)生的變形。Turbine parts from the welding deformation is more than technical design allows the deformation range, should try to to correct, to conform to the requirements of the quality of the product. Practice has proved that most of the deformation of the component can be correct. Correction methods are trying to cause a new deformation to achieve offset has happened.在生產(chǎn)過程中普遍應(yīng)用的矯正方法,主要有機(jī)械矯正、火焰矯正和綜合矯正。但火焰矯正是一門較難操作的工作,方法掌握、溫度控制不當(dāng)還會(huì)造成構(gòu)件新的更大變形。因此,火焰矯正要有豐富的實(shí)踐經(jīng)驗(yàn)。本文對(duì)水輪機(jī)部件焊接變形的種類、矯正方法作了一個(gè)粗略的分析。Correction methods in general use in the process of production, the main have mechanical correction, flame straightening and comprehensive correction. But the flame correction is a more difficult operation work, improper control, temperature control also creates new bigger deformation. Therefore, flame correction should have rich experience in practice. In this paper, a correction of welding deformation type turbine components, method makes a rough analysis.1 水輪機(jī)部件焊接變形的種類與火焰矯正1 the kinds of welding deformation and flame straightening turbine parts水輪機(jī)部件的主要構(gòu)件是焊接H型結(jié)構(gòu)(如座環(huán))、箱體結(jié)構(gòu)(如頂蓋,底環(huán))、支撐結(jié)構(gòu)。焊接變形經(jīng)常采用以下三種火焰矯正方法:(1)線狀加熱法;(2)點(diǎn)狀加熱法;(3)三角形加熱法。下面介紹解決不同部位的施工方法。The turbine parts of main component is welded H structure (such as seat ring), enclosure structure (such as roof, bottom ring), support structure. Welding distortion often use the following three methods of flame correction: (1) linear heating method; (2) dot heating method; (3) triangular heating method. To solve different parts of the construction method is described below.以下為火焰矯正時(shí)的加熱溫度(材質(zhì)為低碳鋼)Flame correction for the temperature (is made of mild steel,低溫矯正 500度600度 冷卻方式:水Low temperature correction cooling way: 500 600 degrees of water中溫矯正 600度700度 冷卻方式:空氣和水In 600 700 degrees temperature correction cooling: air and water高溫矯正 700度800度 冷卻方式:空氣High temperature correction 700 800 degrees cooling: air注意事項(xiàng):火焰矯正時(shí)加熱溫度不宜過高,過高會(huì)引起金屬變脆、影響沖擊韌性。16Mn在高溫矯正時(shí)不可用水冷卻,包括厚度或淬硬傾向較大的鋼材。Note: flame correction when the heating temperature is unfavorable and exorbitant, become fragile, too much can cause metal impact toughness. 16 mn in high temperature correction is water cooling, including the tendency of hardenability thickness or larger steel.1.1座環(huán)環(huán)板及頂蓋、底環(huán)蓋板的上拱與下?lián)霞皬澢?.1 seat inside board and the top plate, bottom ring under the arch and the torsion and bending一、在座環(huán)環(huán)板及頂蓋、底環(huán)蓋板上,對(duì)著縱向焊縫,由中間向兩端作線狀加熱,即可矯正彎曲變形。為避免產(chǎn)生彎曲和扭曲變形,兩條加熱帶要同步進(jìn)行。可采取低溫矯正或中溫矯正法。這種方法有利于減少焊接內(nèi)應(yīng)力,但這種方法在縱向收縮的同時(shí)有較大的橫向收縮,較難掌握。A, here inside board and the top and bottom ring plate, to the longitudinal weld, from middle to both ends of line heating, bending deformation can be corrected. In order to avoid bending and torsion deformation, two tropical to synchronize. Can take corrective or medium temperature correction method at low temperature. This method is beneficial to reduce welding stress, but this method at the same time of longitudinal contraction have larger transverse contraction, more difficult to master.二、座環(huán)環(huán)板及頂蓋、底環(huán)蓋板上作線狀加熱,在固定導(dǎo)葉或肋板上作三（版權(quán)聲明：本文轉(zhuǎn)載自論文網(wǎng)在線()，版權(quán)歸原作者所有。）角形加熱。用這種方法矯正座環(huán)環(huán)板及頂蓋、底環(huán)蓋板的彎曲變形,效果顯著,橫向線狀加熱寬度一般取2090mm,板厚小時(shí),加熱寬度要窄一些,加熱過程應(yīng)由寬度中間向兩邊擴(kuò)展。線狀加熱最好由兩人同時(shí)操作進(jìn)行,再分別加熱三角形三角形的寬度不應(yīng)超過板厚的2倍,三角形的底與對(duì)應(yīng)的翼板上線狀加熱寬度相等。加熱三角形從頂部開始,然后從中心向兩側(cè)擴(kuò)展,一層層加熱直到三角形的底為止。加熱固定導(dǎo)葉或肋板時(shí)溫度不能太高,否則造成凹陷變形,很難修復(fù)。2, seat inside board and the top, bottom ring linear heating cover, on the fixed guide vane or floor three (net of paper of copyright statement: this article reprinted from online (), all peer originator.) Angle of heating. Corrected by this method inside board and the top and bottom ring plate of the bending deformation, the effect is remarkable, transverse linear heating width generally take a 20-90 mm, thickness, heat width is narrow, heating process should be the width on both sides to expand in the middle. Linear heating is best done by two people at the same time operating, then respectively heating triangle triangle width should not be more than thickness of 2 times, at the bottom of the triangle with a width equal to the corresponding linear heating on the wing. Heating starting at the top of the triangle, and then expanding from the center to both sides, layers of heating until the end of the triangle. Fixed guide vane or floor heating when the temperature not too high, cause otherwise sag deformation, difficult to repair.1.2座環(huán)環(huán)板及頂蓋、底環(huán)蓋板的波浪變形1.2 inside board and the top and bottom ring plate of the wavy deformation矯正波浪變形首先要找出凸起的波峰,用圓點(diǎn)加熱法矯正。加熱圓點(diǎn)的直徑一般為5090mm,當(dāng)鋼板厚度或波浪形面積較大時(shí)直徑也應(yīng)放大,可按d=(4+10)mm(d為加熱點(diǎn)直徑;為板厚)計(jì)算得出值加熱?？咀鞆牟ǚ迤鹱髀菪我苿?dòng),采用中溫矯正。當(dāng)溫度達(dá)到600700度時(shí),將手錘放在加熱區(qū)邊緣處,再用大錘擊手錘,使加熱區(qū)金屬受擠壓,冷卻收縮后被拉平。矯正時(shí)應(yīng)避免產(chǎn)生過大的收縮應(yīng)力。矯完一個(gè)圓點(diǎn)后再進(jìn)行加熱第二個(gè)波峰點(diǎn),方法同上。為加快冷卻速度,可對(duì)Q235鋼材進(jìn)行加水冷卻。這種矯正方法屬于點(diǎn)狀加熱法,加熱點(diǎn)的分布可呈梅花形或鏈?zhǔn)矫茳c(diǎn)形。注意溫度不要超過750度。Correction must first find the bump of the wave, wave deformation correction with dot heating method. Heating of dots is 50 90 mm in diameter, and when the thickness of steel plate or wavy area larger diameter should also enlarge, can press d = (4 delta + 10) mm (d to add hot spot diameter; the delta for thickness) heating value is calculated. Baked mouth from wave crest make spiral movement, using the temperature correction. When the temperature of 600 700 degrees, put hammer heating zone edge, reoccupy hammer hammer, and make the heating area of metal by extrusion, cooling contraction after leveling. Correction should avoid excessive shrinkage stress is produced. Finish recruit a dot after the heat wave point, the second method is same as above. In order to speed up the cooling speed, can be add water cooling for Q235 steel. This correction method belongs to the dot heating method, add the hot spot can show the distribution of the plum flower form or chain dense point form. Pay attention to the temperature does not exceed 750 degrees.1.3支撐結(jié)構(gòu)的角變形1.3 Angle deformation of the support structure矯正支撐結(jié)構(gòu)角變形。在筋板的上面(對(duì)準(zhǔn)焊縫外)縱向線狀加熱(加熱溫度控制在650度以下),注意加熱范圍不超過兩焊腳所控制的范圍。線狀加熱時(shí)要注意:(1)不應(yīng)在同一位置反復(fù)加熱;(2)加熱過程中不要進(jìn)行澆水。這兩點(diǎn)是火焰矯正一般原則。Correct Angle of supporting structure deformation. Aim on the top of the stiffened plates (weld) longitudinal linear heating (heating temperature control at 650 degrees Celsius), pay attention to heat the scope not more than two legs control range. Linear heating should pay attention to: (1) should not be in the same place repeatedly heating; (2) not to water in the heating process. These two points is a correction of flame general principles.2 結(jié)語2 in the火焰矯正引起的應(yīng)力與焊接內(nèi)應(yīng)力一樣都是內(nèi)應(yīng)力。不恰當(dāng)?shù)某C正產(chǎn)生的內(nèi)應(yīng)力與焊接內(nèi)應(yīng)力和負(fù)載應(yīng)力迭加,會(huì)使部件的縱應(yīng)力超過允許應(yīng)力,從而導(dǎo)致承載安全系數(shù)的降低。因此在水輪機(jī)部件制造中一定要慎重,盡量采用合理的工藝措施以減少變形,矯正時(shí)盡量可能采用機(jī)械矯正。當(dāng)不得不采用火焰矯正時(shí)應(yīng)注意以下幾點(diǎn):Flame straightening as stress and the welding stress is caused by internal stress. Inappropriate and the internal stress produced by orthodontic welding stress and load stress