第一旋风分离器斜插管划线开孔组装焊接方案

1、放样模板可划出模拟件轨迹模拟件分离器筒体用模拟件划出筒体开孔线划开孔线等距离偏移动用于测量开 孔1.分离器筒体放置在TK6926S数控镗铣床工作平台上,校正相对位置。2.在图示起点钻孔作为起割点3.开孔程序编入镗铣床数据库中,割刀头沿划线轨迹先走一次,在运行过程中校正，使走的轨迹基本与划线基本一致。4.从起割点开始切割。切割方向如图所示。切割到A-A点停止,后面部分在镗床进行机加工。5.对气割表面进行修磨，打磨至少2mm厚HAZ金属，打磨光洁度平整度应满足焊接的要求。6.坡口表面100%MT检查合格后,开始装配和焊接。切割轨迹图TK6926数控镗铣床机床参数：X轴160000mm，y轴6000

2、mm，z轴1500mm，W轴1500mm，镗杆直径260mm，回转工作台4000mm*4500mm，最大承重80吨。TK6926数控镗铣床机床参数45度筒体接头(筒体3-3筒体3-6筒体3-7B155 3012653450N79N61N62N7650.2N80N52.2N52.3N53.1N53.2N52.1N52.4划线划线:内外壁放样划线并打洋冲标示内外壁放样划线并打洋冲标示 (基准线和气割线基准线和气割线)。 Marking: Sampling marking inside and outside of the wall and punch mark ( base line and ga

3、s cutting line).钻气割孔（试割孔和正式孔）钻气割孔（试割孔和正式孔） Opening( try opening and official opening)在镗铣床机头上装妥斜孔自动开孔工装在镗铣床机头上装妥斜孔自动开孔工装 并装妥气割喷嘴。并装妥气割喷嘴。 Assemble slanting hole auto opening fixture N5092-470 on the head of boring and milling machine and assemble air cutting nozzle将产品吊至镗铣床平台上并校调将产品吊至镗铣床平台上并校调 （0在最高点，

4、轴线调水平并与机床镗轴垂直）。在最高点，轴线调水平并与机床镗轴垂直）。 Lifting the product on the platform of boring and milling machine and regulate.(0 is the highest point, adjust axis to level and perpendicular with machine boring axis.)镗铣床上输入自动走轨迹的程序（分二部分），并校调中镗铣床上输入自动走轨迹的程序（分二部分），并校调中 心后按划线试走轨迹，符合要求后才能在产品上气割。心后按划线试走轨迹，符合要求后才能在产品

5、上气割。Input auto-moving track program on boring and milling machine (separate into 2 parts), and try track according to marking after adjust the center. Gas cutting the product after it complies with requirements.装妥隔热装置。装妥隔热装置。 (在筒体与镗铣床之间用槽钢制一架子用在筒体与镗铣床之间用槽钢制一架子用 石棉布隔热，并且在地面上用石棉布覆盖。）石棉布隔热，并且在地面上用石棉布覆盖

6、。）Assembly heat insulation device.( Produce one structure which is made of stiffness in between the shell and boring and milling machine. Insulate heat with asbestos cloth. And covered by asbestos cloth on the ground.)预热、试割（预先编程）预热、试割（预先编程） Preheating and try cutting( advance progress)预热、正式在产品上气割开孔预

7、热、正式在产品上气割开孔（分二部分）（分二部分）。Preheating and official cutting on product( separate to 2 parts)去渣并修磨去渣并修磨45斜孔至尺寸。斜孔至尺寸。Slag removing and repair grinding 45 slanting hole so that it can reach to required size.坡口各尺寸及表面光洁度测量。坡口各尺寸及表面光洁度测量。Groove size and surface cleanness checking.45斜孔坡口斜孔坡口MT检查。检查。 45 slant

8、ing hole groove MT checking.气割气割Gas cutting开孔开孔Opening筒体3-16衬垫筒体3-4297装配和检查装配和检查 Assembly and inspectionA：将筒体吊至装配位置并校调（轴线调水平）。：将筒体吊至装配位置并校调（轴线调水平）。Lifting shell in assembly position and adjust it ( Axis shall be in level).B：装焊妥筒体上产品吊轴和二只工装吊耳（在：装焊妥筒体上产品吊轴和二只工装吊耳（在180方位离方位离 端端 口口1000mm）及）及内壁的定位工装。内壁的定

9、位工装。Assemble and weld product lifting shaft and two lifting lugs on shell(on 180 position and 1000mm away from end) and inside wall positioning layout .C：对产品进行校调（：对产品进行校调（0在最高点）。在最高点）。Adjust product(0 is the highest point).D：斜接管内壁装焊定位块。斜接管内壁装焊定位块。外壁上装焊起吊吊耳（三只），外壁上装焊起吊吊耳（三只）， 在筒体上装焊测量工装在筒体上装焊测量工装 。Sl

10、anting tube inside wall assemble and weld positioning pieces. Assemble and weld 3 lifting lugs outside wall.E：装配斜接管并校调装配斜接管并校调45夹角，检查配合。夹角，检查配合。Assemble slanting nozzle and adjust 45 angle and check fit up.F：装妥防变形工装及焊接垫板。装妥防变形工装及焊接垫板。Assemble anti-distortion fixture and weld mat plate.斜管外侧坡口部位打斜管外侧坡

11、口部位打磨磨Grind slanting tube groove outside MT检查检查MT testing葫芦安装（工葫芦安装（工装）装）Fixture assembly内壁的定位工装内壁的定位工装测量测量Positioning fixture measurement焊妥防变形工装焊妥防变形工装 （局部预热）（局部预热）Fixture for prevent deformation( Local HT)焊妥衬板焊妥衬板Weld scaleboard测量角度测量角度Angle measurement初装加热装置（热电偶）并焊妥初装加热装置（热电偶）并焊妥Add thermocouples

12、 and welding装焊临时稳固工装装焊临时稳固工装Assemble temporary stable fixture 测量测量Measurement装加热工装（热电偶）装加热工装（热电偶）Add thermocouples焊接焊接 Welding 焊接工艺焊接工艺 Welding procedure焊接工艺采用直流埋弧自动焊，局部和外侧加强高采用直流手工电弧焊接工艺采用直流埋弧自动焊，局部和外侧加强高采用直流手工电弧焊，有关参数如下：焊，有关参数如下：Welding procedure apply direct current SAW, local and outside reinfor

13、ce. Apply direct current Manual SMAW, related parameter is as follows:预热温度：预热温度：200230；层间温度：；层间温度：200250Pre-heat Tem: 200230；Interpass Tem: 200250埋弧焊：焊接电流：埋弧焊：焊接电流：500600A；电弧电压：；电弧电压：3035V；极性：；极性：DCEPSAW: Welding current: 500600A；Arc voltage: 3035V；Polarity: DCEP焊接速度：焊接速度：450550mm/min；Welding speed:

14、后热规范：后热规范：30035046h；Post heating specification:焊接位置：平焊焊接位置：平焊Welding position: Slip-on welding 焊机改装和调试 Welding machine debug1.装焊机平台装焊机平台Assemble welding machine platform2.敲测量洋冲眼敲测量洋冲眼Punching3.加热加热 Heating4.防变形马脚和塞块焊接防变形马脚和塞块焊接Weld anti-deformation support and plug5.装焊机装焊机Assemble welding machine2#4

15、#6#8#10#9#7#7#5#3#1#11#12#12#9#10#11#8#6#5#4#3#2#1#0318-3-4筒体焊缝洋冲眼处于0318-3-16筒体内侧搭建工作搭建工作平台平台Assemble platform提升焊机提升焊机Lifting welding machine焊剂临时档板焊剂临时档板Temporary baffle焊接、测量监控焊接、测量监控 Welding, measurement check焊妥后去氢处理焊妥后去氢处理 De-hydrogen treatment after welding去氢后不低于去氢后不低于200 时割时割/去除防变形工装和衬垫去除防变形工装和衬

16、垫 After De-hydrogen treatment, Cutting/remove anti-deformation fixture and backing strapwhen it is about 200 .打磨，打磨，测量测量，焊缝焊缝MT，RT，UT Grinding, measurement, MT，RT，UT testing the weld预热预热 Preheating外侧加强高手工焊焊妥外侧加强高手工焊焊妥 Manual welding outside reinforcement 去氢去氢De-hydrogen 打磨打磨Grinding；MT，UT，RT 测量测量Mea

17、surement45 焊焊 接接 方方 法法Welding methodSMAW, SAW 工艺评定报告编号工艺评定报告编号Welding qualification record No. 适适 用用 范范 围围Application45筒体焊接45 Shell welding 坡坡 口口 形形 式式Groove style详见产品图纸 Refer to drawings 衬衬 垫垫/ 焊焊 接接 位位 置置Welding position1G（平焊）/3G、2G1G(Slip-on) /3G、2G 基基 本本 金金 属属 材材 料料 Basic materialSA516Gr70 厚厚 度度

18、 范范 围围Thickness range200mm 焊接材料（焊丝焊焊接材料（焊丝焊 焊丝-焊剂：F8P0-EA2 4.0mm 焊条：E7015 4.0、5.0mm 焊焊 机机 直流埋弧焊机直流手工电弧焊机 条、焊剂牌号及规条、焊剂牌号及规 格）格） 保保 护护 气气 体体/ 流流 量量/ 预预 热热 温温 度度180 最最 高高 层层 间间 温温 度度250 最最 低低 保保 温温 温温 度度200直至焊后去氢或中间热处理 后后 热热 温温 度度300350 保保 温温 时时 间间4Hr 中间焊后热处理温度中间焊后热处理温度注（1） 保保 温温 时时 间间注（1） 冷冷 却却 方方 式式注

19、（1） 最终焊后热处理温度最终焊后热处理温度注（2） 保保 温温 时时 间间注（2） 冷冷 却却 方方 式式注（2） 焊接参数：焊接参数： 极性：直流反接埋弧自动焊 手工电弧焊规格：4.0mm 4.0mm 5.0mm电流：500600A 130180A 170220A电压：2834V 2228V 2228V速度：350450mm/min 注：（1）HT(V)-124（2）HT(V)-123 焊接操作技术及顺序：焊接操作技术及顺序：1、焊前清理：装焊前坡口表面及其邻近区域按JB4730作100%磁粉检查，合格后对其表面进行清理，包括马脚、引熄弧板等，以去除表面油污、锈迹等杂物。2、按冷作过程卡要

20、求进行装配，如图1。按图2所示用洋冲打上测量焊接变形的洋冲眼，编号标志，并测量对应洋冲眼之间的距离和做好记录。3、按规程进行预热，并焊妥内壁防变形筋板（工装： 马脚）。测量对应洋冲眼之间的距离和做好记录。4、维持预热温度，用埋弧自动焊或手工电弧焊方法将接头下侧坡口底部适当焊平，如图3中W-1焊缝。5、测量对应洋冲眼之间的距离和做好记录。分析焊接变形情况。6、继续埋弧自动焊焊接，如图3中W-2焊缝。每焊接10mm、20mm、50mm、50mm、100mm、100mm和焊至筒体内表面后测量对应洋冲眼之间的距离和做好记录。分析焊接变形情况。该处焊缝要求连续焊接。7、继续埋弧自动焊焊接，如图3中W-3

21、焊缝。两侧必须对称焊接，一侧连续焊接厚度不得大于10mm, 必须焊接另一侧，以减少焊接残余变形。每焊接100mm、200mm、200mm、500mm、500mm、500mm后测量对应洋冲眼之间的距离和做好记录。分析焊接变形情况。该处焊缝最好连续焊接。8、继续埋弧自动焊焊接，如图3中W-4焊缝。9、焊后测量对应洋冲眼之间的距离和做好记录。10、按规程进行后热处理。11、后热处理后在焊缝温度大于200时移去电红外加热板并立即吊装进炉进行中间热处理。12、工件温度200左右时出炉，在工件温度不低于150时气割和/或碳弧气刨去除所有防变形工装和筋板以及焊缝高出内壁表面的引熄弧部分。打磨平整，圆滑过渡，

22、MT检查。13、对焊缝进行100%MT、100%RT和100%UT检验。14、吊装工件至合适的位置。 15、按规程进行预热。16、手工焊焊接外侧加强高。17、手工焊焊接外侧加强高。18、立即按规程进行后热处理。19、打磨加强高焊缝表面，尺寸和加强高满足图纸规定要求。20、对整条焊缝进行100%RT、100%UT、100%MT检查。Welding operation technology and sequences:1.Cleaning before welding: Before assembly and welding, 100%MT to groove surface and its ad

23、jacent area according to JB4730. Cleaning after it is accepted, including supports, ark plate etc. Remove foreign matters, such as, surface grease, rust etc.2.Assembly according to cold-work progress card requirements. Refer to figure 1. Punch marking according to figure 2 which used for checking we

24、lding deformation. Numbering marking and measure corresponding distance between punch markings and make records.3.Pre-heating and welding inside wall to prevent deformation (fixture: Supports). Measure corresponding distance between punch markings and make records.4.Keep pre-heat temperature. Proper

25、 slip-on welding on the bottom of joint lower side by SAW or SMAW, Such as figure 3, W-1 weld.5.Measure corresponding distance between punch markings and make records. Analysis weld deformation condition.6.Continue SAW welding, see figure 3, weld W-2. Measure corresponding distance between punch mar

26、kings and make records after every welding 10mm、20mm、50mm、50mm、100mm、100mm and weld to shell inside surface. Analysis welding deformation condition. This area of weld requires continuous welding.7.Continue SAW welding, see figure 3, weld W-3. Both sides need to symmetrical welding. One side continuo

27、us welding thickness can not larger than 10mm. Must weld the other side to reduce welding residual deformation. Measure corresponding distance between punch markings and make records after every welding 100mm、200mm、200mm、500mm、500mm、500mm and weld to shell inside surface. Analysis welding deformation condition. It is better to use continuous welding for this area of weld.8.Continue SAW welding, see figure 3, weld W-4.9.After welding, measure corresponding distance between punch markings and make records. 10.Proceed post heat treatment .11.After post heat treatment, remove e