中英文对照翻译-封头加工工艺Head-processing-technology

PAGE22毕业设计（论文）外文翻译外文题目：Headprocessingtechnology译文题目：封头加工工艺2012年3月11日Headprocessingtechnology1.weldingprocess1.1weldingoperationOurfactorycommonweldingmethodsare:manualwelding,argonarcwelding,submergedarcwelding.(1)manualweldingismainlyusedforcarbonsteel3-6mmplatewelding.(2)submergedarcweldingtomorethan8mmcarbonsteelstainlesssteelsheetweldingmainly.(3)3-6mmstainlesssteelargonarcweldingwithweldingmainly.CommonlyusedstainlesssteelwireER304andER316Lsteelwire,commonlyusedtoJ422andJ507andJ426andJ427low-temperatureweldingconsumables.FluxofcarbonsteelusedistheHJ431,stainlesssteelcommonlyusedisHJ260,.Asaresultofweldingwirefluxcanbeeasilyaffectedwithdamp,storedintheinfrareddryingmachine,fluxHJ431andHJ260dryingtemperatureis250-300℃.WeldingwireJ422andJ350dryingtemperaturewere150℃and300℃Weldingprocessiscompletelyinaccordancewiththe"welding"execution,sheetthicknessdeterminestheweldingtoweldingordoublesidedarcweldinginwelding,aftertheweldseaminspection(RTXray)judgmentwithoutpores,cracksandotherdefects,suchasfoundintheabovedeficiencies,totherepair,untilthefilming.1.2weldingoperationstandard(1)weldingprocedurecardafterreceivingprocess,affirmtheprocesscardandphysicalmaterial,quantity,unitnumber,specifications,sizeinstructionnumberisconsistent,whetherthereisdebrisaroundthewafer,wafersplasheswhethercleanremoval,suchastreatmentisnotclean,willusethegrindingclean.(2)thereisnoweldingtestplate,groovecuttingqualitycanmeettherequirement,materialsurfacewithoutobviousdefects,suchasabnormalresponse.(3)accordingtothe"Regulations"weldingprocedurecardcheckofweldinggroovetypeanddimensionscorrespondto.(4)oneachsideofgroovesurfacegrinding,buttedgeoffsetisnotgreaterthanthe10%thickness,andnotmorethan1.5mm.(5)pointfixedthefirstweldlayerterminalweldinglengthnotlessthan50mm,arcboardspecificationsshouldbe150*150mmandamaskhavingRarc,teamroundsshouldbegivenwithin8hoursofwelding,ortouseflametothemoistureinsidethebakinggroove.(6)thewelderholds"welding"and"weldingrecords"forweldingconsumables,weldingtwoclasslibraryforregistration,usingfluxfieldvolumeshouldnotexceed4hours,ortocontinuetobackintotheovendrying.(7)a,preheatingplatethicknessnotlessthan30mmcarbonsteel,lowalloysteel,thepreheatingtemperatureofweldingprocessby"card","standard"provisionsoftheweldingtechnology.B,preheatingrangewidthnotlessthan4mmandnolessthan100mm.C,intheprocessofweldinggrooveatanytimetemperatureshallnotbelessthantheprescribedtemperature.D,whenweldingtemperatureisbelow0℃(arbitrarythickness)mustbeheatedto15℃oraboveinordertowelding.(8)abeforewelding,weldingtoweldingequipmentinspection,examinationwasnormalbeforeweldingfacilities.AccordingtoB,""therequirementsofweldingprocesswelding,weldingandfillintherecordsC,welding,weldinglayersshallbeinaccordancewith"welding"requirements,weldingshallnotbealargecurrent,lesslayers.(9)removaloftheroota,stainlesssteelcleaningbeforetherootgroovesides,withintherangeof300mm,splashingpaintcoating.B,usingcarbonarcairgouging,shouldbeselectedaccordingtotherequestcarbonroddiameter.C,rootcleaning,grindingcleaninggrooveandtwosidetheexistenceofcarburizedlayer,oxide,slagandothersundries.Grindingwidth:manualwelding,rust,oxideabove20mm,oil30mmabove,automaticwelding,rust,grease,oxides25mm50mmgrooveinnergrindingrequirements,carbonsteel,lowalloysteelδn≤10mmweld,itstwoendswithintherangeof300mmcarburizedlayermustbecompletelyremoved,therestpartallowstheremovalofmorethan50%.Othernon-ferrousmetalsmustbecompletelyclear.[3]D,rootcleaning,compositesteelCr-Mo,manualweldingandthethicknessofδn≥30mmweldsshallbeexaminedbyPT.(10)duringtheprocessofweldingdefectrepairbyweldingrepairweldingrepairmonitorinstructionexperiencedweldersas.Repairweldingprocessshouldeliminatesolderingphenomenon,orpolishedafterwelding,thefollowingdefectsmustberemovedbeforeweldingtoweldingcrack,①partial②③pitsthestomaAshallnotbelowerthantheparentmaterial,weld.B,thereshallbenoundercutting.C,withoutremovingtheresidualhighseam.Thesurfaceshallnothavecracks,pores,crater,undercutandslaginclusions,andmaynotretaintheslagandspatter.D,removalofresidualhighweldinspectionshallnothaveanydefectdisplayPT.E,suchasthedefectsofcarbonsteel,low-alloysteelrepairprocedures:agrindingwheeloracarbonarcgougingpolishingcleaning→PTcheckgrindergrindingouttheweldinggroove,welding,PT,stainlesssteelrepairprocedures:agrindingwheeloracarbonarcgougingpolishingcleaning→PT(δn≥2mmneed)→grinderpolishedtoaweldinggroovewelding→PTexamination.[4](12)weldedinternalrework,repairprocedures:locationofdefect,defectremoval→PT→→removalcheckweldingweld→PTexamination.[5](13)accordingtoRTfilm,RTstaffandtheweldersinweldingseamtogetherdeterminethelocationofdefects,includingthefollowingrequirementswhenusingUTtodeterminethedefectposition,thefirstrepairδn≥30mmuseUTtodeterminethelocationofdefects,twoorthreerepairδn≥20mmusingUTtodeterminethedefectposition,UTpositioningbyRTafterclass.Thepositionanddepthofdefect(calibrationsideshallbethedepthofdefect≤1/2side).(14)aftertheweldinginspectorormonitorbyconfirmed,intheprocesscardsignedyournameandobjecttogetherwithtransfertothenextprocess,bythenextprocessresponsibilityrecognitioncan.2.stampingprocess2.1stampingoperationStampingoperationissmallheadforminganimportantoperation.Thesamestampingisalsoheadofthecracking,thinningappearedmostprocesssection.2.2punchingmachine.(1)themastercylinderismainlyusedtoconnectthediehead,istheheadformingthenecessaryparts.(2)sidecylinderusedforpressingdiering,fixingtheupperandlowermoldringofheaddisk.Theheadinthepressingprocessistopreventthecrease,asanimportantpartofthedrumkit.(3)theoverflowvalveusedforcontrollingthecompressoroverallpressure,preventthewaferduringthepressingprocessoftears.(4)stampingvalveinpressure,stampingvalveonpressurerelief,achieveaveragepressureeffect.Inaddition,circuitboards,motors,circuitboards,storagetank,operationplatform,pedestalarestampingmachinecomponents.2.3.3stampingoperationsteps(1)firstofalltoundertakeablankingprocesscard,findagoodwafer.(2)thecontrolprocesscardonthetechnologicalrequirements,putonasetofcorrespondingdie,andwiththeuseofgaugestodeterminetheselecteddiesizeandtosuppressthewafersize.(3)thewaferisclampedontheupperandlowermoldinsidethecircle,anddeterminethedieheadofthecenterpointandthecenterpointofthewaferinastraightline.(4)theoperationringmoldanddierelativemotion,pressuretest,accordingtothecontrolrodreboundtojudgethesizeofthepressure,therebyregulatingpressuresize.(5)pressuretestend,pressedwafer,stamping.2.3thestampingoperationstandard(1)thecontroltaskorders,confirmphysicalandprocesscardisconsistent,accordingtotheprocesscardconfirmingworkpiecenumber,material,specification,batchnumberandotherfactors,atthesametimecheckwaferendthereisnocrack,burr,polishedwaferwhetheritmeetstherequirements,whetherchamfer,isfacingthegood,therearespecialrequirementswhentheproblemisfound,intimetocontact.(2)accordingtotheprocesscardcorrectselectionofdiemoldsurface,inspection,foundbruisesandseriousinjurymustbepolished,butmustbecleanmoldsurfacecorrosionanddirt.(3)accordingtothetechnologycardsize,shape,texture,straightedgehighertosuppress.(4)thewarm-stamping(accordingtorequirementsheetpropertyisheatedtoacertaintemperature,andthenstampingprocess),toprepareabakinggun,gas,oxygen,percussionwithheadshallpreparethecorrespondingtemplate,double-sidedfilmtothewaferedgeofbothsidesinarangeofabout200-300mmtemplateremoval,andclearthefilmsurface.[6](5)mountedonthelowerdie,asthecasetojointhediepad,thewaferinsideandoutsidesurfacecoatedwithoil,appliedrangeoftopto200-300mm,smearshouldbeuniform,theupperandlowermoldareevenlycoated.(6)thefirstgoldstampinghead,hangingoutwithamodelhead,checksectionshape,atthesametime,checkwhetherthedrumkit,andthereisnothinning,andcheckthesurfacehasnoscratch,hoopprinting,suchasnoneoftheaboveabnormalitiescancontinuetostamping,headforming,sealingsurfacessuchasscratchesaretimelygrinding,andconfirmtheminimumboardthickness,confirmwhetherascratch,strain,curvedpeel,orangepeel,drumkits,wrinkle,hoopprintingetc..(7)suchasaheaddrumkitfoldphenomenonshouldbetogetherwiththecardwiththemovetoreworkprocesstechnology.(8)eachheadshouldbeabletoseetheinstruction,piecenumber,material,ortotransplantation,eachproductspecificationsaftertesting,theprocesscard(tosignthename)togethertothenextprocess,bythenextprocessvalidation.3.pressuredrumprocess3.1pressuredrumoperationPressuredrumprocessandstampingprocessesarethesamestepsintheprocess,stampingprocessrangeofφ159-φ1900mmandpressuredrumprocessisintherangeofφ1600-φ4800mm.Andstampingisdifferentpressuredrummostlytheheadgenerallyforming,eventuallyformingiscompletedbyspinning,stampingwithoutthespecialrequirementsofcustomers,eventuallyformingstepisnotrequired.φ1600-φ1900mmheadsthetwoprocessesisneeded.3.2pressuredrummachine.(1)themaincylinderisprovidedwithanupperdieheadispresseddrumexecutionaslongaspartof.(2)supportingseatfixedlowerdieandupperdieheadcenterinastraightline.(3)supportingframe1isprovidedwitharollingwheel,apositionadjustingbeforeandafter.(4)supportingframeisprovidedwitharollingwheelrotatingdiskII.Inaddition,therearehydraulicsystem,themotor,oilpump,oiltank,andacontrolconsole.3.3pressuredrummachineoperationsteps(1)firstofalltoundertakeablankingprocesscard,findagoodwafer.(2)thecontrolprocesscardonthetechnologicalrequirements,putonasetofcorrespondingdie,andwiththeuseofgaugestodeterminetheselecteddiesizeandtosuppressthewafersize.(3)andstampingmachineisdifferentfromtheoriginalfilmisnotpressuredrumcenterbegantosuppress,butfromthewaferedge,aslongasthedieandwaferalignmentontheline.(4)thepressingprocessiscontinuouslybycontrollingtherotationwheelisdrivenbytherotationofawaferrotating,accordingtoacertainordertosuppress.(5)inafterthepressingprocess,preparedtemplatematching.Ifadeviationtomakefurtheradjustments.3.4pressuredrumoperationstandard(1)dieonthequalityoftheproductsandthesmoothpressuredrumformingcrucial.Therefore,requirethattheoperatormustaccordingtotheprocessingsituationofchoiceformoldandtimelyadjustshimplate.(2)theoperatorreceivestheprocesscard,seeprocesscard,accordingtotheprocesscardcheckobjects,toconfirmtherealinstruction,one-piece,material.Number,batchnumberetc..Accordingtothechoiceofmoldprocesscard.(3)forEHA,EHBheadshapeshaveadoptedthe0.82*Dstandardselection,forDHB,PSH,MDandotherspecialproductsaccordingtotechnologycardselectionofmold,butinprincipleaccordingtoP*0.82/1.15orP*0.82/1.2standardselection.[1](4)pressingcarefullybeforeinspectionwaferquality,noseamwaferendissmooth,thereisnogap,surfacehasnocuttingslaganddefects.(5)aweldinadditiontocarefullychecktheendofthewaferwaferdefects,atthesametimeshouldbecheckedforweldseamishigherthanthatofbasemetal,weldendsofareweldingspatter,weldendgrindingsmooth,thereisnocracknotch.(6)twoortwoormoresuperimposedwhenpressed,eachsliceofthejointsurfaceshouldbeclean,accordingtothecircumstancesmustentrustweldingclass,thewaferisweldedtogethertosuppress.(7)detectionofwaferthickness(thethickest,mostthin,whetherandprocesscard,measurementofwafersizeandprocesscard.(8)suppressionmustberemovedbeforetheinsideandoutsidesurfaceofalldebris,topreventpittingappeared.(9)forgeneralstainlesssteelmaterials(morethan5mmplate)usingTeflonplatemoldandthelowermolddressingonsurfacepolishedsmooth(necessarynowadaysmoldtoTeflonplate.)toensurethesurfacequalityoftheworkpiece,whileintheprocessofthepressingneedtoavoiddebrisintomoldsandsemi-finishedproducts.[6](10)thepressingprocess,whenthewaferisaRshape,mustusethecorrespondingRmodelmeasurement,thepressingprocessshouldbeconsideredtoadjustthepressuredeformationdegree.(11)pressingisfinished,themeasurementofplatethickness,measuringarclength.Checksurfacequality,checkendandweldendissmooth(necessarytopolishouttheceremony).(12)tocheckthesemi-finishedproductwithprocesscardisonthemovetothenextprocess(andsignthename)bythenextprocesstoconfirmacceptancebefore.4.spinningprocess4.1spinningoperationThespinningprocessispressedafterthedrumheadmoldingprocess,mainlyforlargeheadRandstraightedgeformation.4.2spinningmachine.(1)formingwheelisconnectedtothecorrespondingmold,formingintheheadinside,moldtopwithhalfformedheadRandstraightedgeistangenttotangent.(2)supportingwheelisalsoconnectedandmoldedwheelmold,formingintheheadoutside,andaformingwheeltangent.(3)baseforfixinghead,andthebottomaccordingtoheadsizebeforeandaftermoving,theheadshouldbeinstalledsothatthecenterofthebaseandtheheadofthecenterinastraightline.(4)thecenterrodisusedforfixinghead,andthecenterandthecenterofthebaseisinastraightline.Inadditiontothemotor,acircuitboard,isconnectedtotheshaft,andacontrolconsole.4.3spinningprocedure(1)toundertakepressuredrumprocesscard,accordingtothecardtodeterminethecorrespondingheadspinning.(2)accordingtotheheadofthediameter,selectthecorrespondingupperandlowermold.(3)theclampinghead,ensurethattheheadofthecenterpointandthecenterofthebasepointinastraightline.(4)toadjustthemoldingwheelandtheheadoftangent,thenaccordingtotheformingwheelpositionadjustmentroller.(5)inthespinningprocesstoobservetheformingrollerandthesupportingrollerrelativeposition,andcontinuetousethetemplateonthelinealignment.UntiltheRreachestherequirements.4.4spinningoperationstandard(1)spinningwheelmaterialforsteelbearingsorductileiron,moldonthequalityoftheproductsandcanspinformingcloselyrelated,thereforetheoperatormustbeprocessedaccordingtochoosesuitablemold,atthesametime,becauseoftheshapeofthemoldandthesurfaceconditionofthequalityoftheworkpiecehasagreatinfluence,therefore,beforeprocessingandmachiningprocessmustonthemoldforfullinspection.(2)accordingtotheprocesscardrequirements,confirmwafer,pressuredrumorpreloadsemi-finishedinstructionnumber,specifications,quantityofmaterial,compliance,andcheckthequalityofsurfaceandendwithnodefect,abnormaltimelyandontheproceduresofcontact,andinatimelymanner(3)checkthesemi-finishedendissmooth,withorwithoutnotch,crack,surfacehasnocuttingorweldingslag,andshallinspecttheweldseamishigherthanthatofbasemetal,weldendswhetherspatter,weldendgrindingsmooth,thereisnocrack.[7](4)pressuredrumortothepressafterthefinishedproduct,mustcheckforfolding,cracking,crackisnotconducivetothespinningprocessingdefects.(5)forstainlesssteelworkpiece,throughtothepicklingmethodofdecontamination.(6)accordingtotheprocesscardselectionofmold,generalsmallarcrsizerequirementsasabasisforselectingtheinternalwheel.(7)accordingtothedifferentmaterial,thicknessofplateandsheetrebound,selectionisslightlysmallerthantheinternalwheelcirculararcR.(8)forthespecialrequirementsoftheproduct,accordingtoitsshapedesigninsidethewheel,confirmthemoldsurface,goodpolishingprocessing.(9)spinningprocessing,inordertopreventscratchingandimprovetheprocessingperformance,suitablelubricant(grease)topreventprocessheatingheadappearsonthesurfaceofhotcracksandscratches,canalsoprolongtheservicelifeofdie.(10)thespinningprocess,shouldbeconsideredaworkpieceshapingandtimelyforpressureadjustment.(11)afterthemoldingprocess,dealwiththesize,shape,thickness,surfacequalityinspections,confirmation.(12)moldedproductwiththecardwiththetransferprocesstothenextprocess(intheprocesscardsignedtheirname)bytheproceduresundertheinspectorormonitorcheckbefore.5.grooveprocessThe5.1grooveEssentials(1)grooveprocessisaheadofthedata(includingcircumference,totalheight)toachieveJB/T4746standardkeyprocess.[1](2)grooveisinorderandcylinderheadconnectiontime,makeweldingmorethoroughly.(3)themaingroovecuttingprocessandcuttingprocesstools,istheuseofplasmacutting.(4)cutting,accordingtothecardonthetechnologicalrequirements,determinegroovetype(innergroove,outsidethemouth,Xgroove)anddeterminethegrooveangle.(5)thegroovebeforetheheadsplashingagentapplicator.(6)groovewhenthefirsttestslope,thenaprotractormeasuringangle,identifiedinthetolerancerange,afteradjustment,thewholeslope.The5.2grooveoperationstandard(1)accordingtotheprocesscardtofindreal,orderconfirmationNo.,specification,material,batchnumber,quantityandcheckwhethertheworkpiecehasadrumkit,crack,delamination,wrinkle,andwhetherthelossofaround,foundproblemsinatimelymannertocontact,processing,theplatethicknessofmorethan8mm,issuggestedtolosetheroundgroove,thefollowing6mm,toolingplatepressureisgroove.(2)stainlesssteelhead,shouldbeinthegroovewallsmearingsplashfrontheadagent,preventgroove,slagspouttoheadonthewall.(3)headontothebevelingmachinebefore,firstconfirmtheheadweight,basedontheweightofsuitablesling,slingsafetyinspection.(4)headontothegroovemachine,bevelingrotarytableadjustmentscrewrod,withacenteradjustingposition,rotatingtable,isalignedtothecenter.(5)groove,accordingtotechnologycardheightandheighttolerancegrooveheightrulertodrawlines,confirmthehighline,theslopeslope,shouldfirstslopeflatgroove,andthentheslopegroove.(6)outsidethemouthortheinnergrooveangleshouldbecontrolledwithin±2.5tolerance.(7)grooveafter,shouldchecktheheadcircumference,height,straightedge,angle,ifnotqualifiedtorepairprocess,repair.(8)qualifiedheadwillremoveandcleantheslaggrindingheadinternalslag,togetherwithcardtransfertothenextprocess(andsigntheirname)bythenextprocessinspectorconfirmationcanbe.6.polishingprocess6.1polishingprocesssteps(1)accordingtothecardprocessrequirements,identifytheneedforpolishinghead.(2)theheadrotatingtable,determinethelevelof,theclampinghead.(3)polishingfromedgetocenter,orfromthecentertotheedge;accordingtothediametersizedeterminetheheadbeam,lowerspeedandworkingstage,aftermovingspeed.(4)checkthepolishingcondition,appropriateforrework.The6.2polishingoperationstandard(1)accordingtotheprocesscardandmaterialstoconfirmtheproductinstructionnumber,specifications,material,batchnumber,quantity,andcheckwhethertheworkpiecehasadrumkit,crack,delaminationdefects,andwhetherthelossofaround,foundproblemsinatimelymannertocontact,processing,checktheappearance,todeterminetheneedformanualprocessing,thepolishingbeforehookheadtomark.(2)accordingtotherequirementsofthechoiceofusingapolishing,polishingpads,andthenecessaryauxiliarytool.(3)confirmtheheadweight,basedontheweightofsuitablesling,andcheckwhetherthesafetyhanger.(4)theheadhangingontoaworktable,adjustthecenter,atthesametimetoensurethattheheadisinthebasiclevel(0-5deviations).(5)peopleinthescenewhenpolishingpolishing,attention,especiallytheleftcentre,speedfast,oroutwardfromacenterleft,alittlepressuretoincrease,fromtheedgetothecenterofpressureduringpolishing,toalittledecreaseinpolishinghead,thinwall,asthecasemaybemountedshockproofwheel,atthesametimeattentiontomechanicalworkhasnoabnormal.(6)afterthecompletionofinspectionheadpolishing,withorwithoutdefect,andthenecessarycontact.(7)thePolishwellheadwithcoatedpackaging,intheprocesscardsignedtheirnames,togetherwiththeheadandprocessthecardwiththecirculationstorage,andbythenextinspectionapproval.封头加工工艺1.焊接工序1.1焊接操作我们厂常用的焊接方法有：手工焊、氩弧焊、埋弧焊。（1）手工焊主要用于碳钢3-6mm板材的焊接。（2）埋弧焊以8mm以上碳钢不锈钢板材的的焊接为主。（3）氩弧焊以3-6mm不锈钢的焊接为主。常用的不锈钢焊丝有ER304和ER316L等，碳钢常用焊丝以J422和J507等和低温焊材J426和J427。焊剂碳钢常用的是HJ431，不锈钢常用的是HJ260,。由于焊丝焊剂易受潮，平时将焊丝焊剂储存在红外线电子烘干机内，焊剂HJ431以及HJ260的烘干温度为250-300℃。焊丝J422以及J350的烘干温度分别为150℃和300℃焊接工序是完全按照《焊接工艺》执行的，板材的厚度决定了焊接时需要单面焊或者双面焊，在焊接结束后要对焊缝进行RT探伤（X射线）判断有没有气孔，裂纹等缺陷，如发现以上缺陷，要进行返修，直至拍片过关。1.2焊接作业标准（1）焊接工序接到工艺流转卡后，确认工艺流转卡和实物的材质，数量，单件号，规格，大小片的指令号等是否一致，圆片周围是否有杂物，圆片上的飞溅物是否去除干净，如没有处理干净，就要用砂轮打磨干净。（2）有无焊接试板，坡口切割质量能否达到要求，材料表面有无明显缺陷，如发现异常要及时反应。（3）根据《焊接工艺卡》的规定检查焊接坡口形式及尺寸是否符合。（4）每侧坡口面打磨，对接错边量不大于10%板厚，且不大于1.5mm。（5）点固第一层焊缝终端处电焊长度不小于50mm，收弧板规格应为150*150mm且一面具有R的圆弧，组队后的圆片应在8小时内焊接，否则须用火焰烘去坡口内的水分。（6）焊工持《焊接工艺》与《焊接记录》领取焊材，焊材二级库处进行登记，领用的焊剂现场放量不得超过4小时，否则要放回烘箱继续进行重新烘干。（7）预热a、板厚不小于30mm的碳钢，低合金钢，预热温度按《焊接工艺卡》、《焊接技术标准》的规定进行。b、预热范围宽度不小于4mm且不小于100mm。c、在焊接过程中任何时候坡口处温度不得低于规定的预热温度。d、当焊件温度低于0℃（任意板厚）时必须预热到15℃以上才能进行焊接。（8）焊接a、焊接前必须对焊接设备进行检查，检查正常后方可施焊。b、按《焊接工艺》的要求焊接，同时填写焊接记录c、焊接规范，焊接层数须符合《焊接工艺》的要求，焊接时不得采用大电流，少层数。（9）清根a、不锈钢清根前，坡口两侧各300mm范围内，涂防飞溅涂料。b、采用碳弧气刨清根时，应按要求选用碳棒直径。c、清根后，砂轮打磨清理坡口及两侧存在着渗碳层，氧化物，熔渣等杂物。打磨宽度：手工焊、锈、氧化物20mm以上，油污30mm以上，自动焊，锈，氧化物25mm、油污50mm坡口内侧打磨要求，碳钢，低合金钢δn≤10mm的焊缝，其两端各300mm范围内渗碳层必须彻底清除，其余部分允许清除50%以上。其他有色金属必须彻底清除。[3]d、清根后，复合钢Cr-Mo钢，手工焊及板厚δn≥30mm的焊缝应进行PT检查。（10）焊接过程中缺陷返修返修焊工由焊接班长指令返修经验丰富的焊工担任。补焊过程中应杜绝粘焊现象，否则经打磨后再补焊，下列缺陷必须清除后方才继续焊接，①焊偏②裂纹③凹坑④气孔a、焊缝不得低于母材。b、不得有咬边现象。c、不去除余高的焊缝。其表面不得有裂纹、气孔、弧坑、咬边和夹渣等缺陷，并不得保留有熔渣和飞溅物。d、去除余高的焊缝PT检查不得有任何缺陷显示。e、如有缺陷①碳钢，低合金钢返修程序：砂轮或碳弧气刨打磨清理→PT检查→砂轮机打磨出焊接坡口→焊接→PT检查，不锈钢返修程序：砂轮或碳弧气刨打磨清理→PT检查（δn≥2mm时需要）→砂轮机打磨出焊接坡口→焊接→PT检查。[4]（12）焊接内部返修，返修程序：缺陷定位→缺陷去除→PT检查→焊接→去除焊缝余高→PT检查。[5]（13）参照RT底片，RT人员与焊工一同在焊缝上确定缺陷位置，将含下列要求时采用UT确定缺陷位置，一次返修δn≥30mm时采用UT确定缺陷位置，二、三次返修δn≥20mm采用UT确定缺陷部位，UT定位后由RT班标出缺陷位置和深度（标定侧须为缺陷深度≤1/2侧）。（14）焊接完毕后由检验员或班长确认后，在工艺卡上签上姓名并连同实物一起流转至下道工序，由下道工序责任人认可才可以。2.冲压工序2.1冲压操作冲压操作是中小型封头成型的重要操作。同样冲压也是封头的开裂，减薄出现最多的工序段。2.2冲压机的构成（1）主缸主要用于连接模头，是封头成型的必要部件。（2）边缸用于压住上模圈，固定住上下模圈中的封头圆片。是防止封头在压制过程中折皱，鼓包的重要部件。（3）溢流阀用于控制控制压机的整体压力，防止圆片在压制过程中发生撕裂。（4）冲压阀在压力过大时，冲压阀会对压力进行缓解，达到压力平均的作用。除此之外，油路板、电机、油路板、储油箱、操作台、底座等都是冲压机的组成部分。2.3.3冲压的操作步骤（1）首先承接了下料工序的流转卡后，找到对应下好的圆片。（2）对照工艺流转卡上的工艺要求，换上对应的一套模具，且用量具确定所选用的模具尺寸和要压制的圆片尺寸吻合。（3）将圆片装夹在上下模圈内，并且确定模头的中心点与圆片中心点在一条直线上。（4）操作上模圈以及模头的相对运动，进行试压，根据控制杆的反弹力度判断压力大小，从而调节压力大小。（5）试压结束，压紧圆片，进行冲压。2.3冲压作业标准（1）对照任务单，确认实物与工艺卡是否一致，根据工艺卡确认被加工工件的数量，材质、规格、炉批号等要素，同时检查圆片端部有无裂纹，毛刺，打磨是否符合要求，圆片是否有倒角，是否正面朝上等，有特殊要求时，发现问题则及时联络。（2）根据工艺卡正确选用模具，检查模具表面情况，发现伤痕和严重拉伤必须打磨，同时须清理模具表面的锈蚀等污物。（3）根据工艺卡要求的尺寸，形状、材质、直边高等情况进行压制。（4）要求温冲（根据板材性质加热到一定温度，然后进行冲压的工艺）时，须准备烘枪、煤气、氧气、冲旋结合的封头则须准备相应的样板，双面贴膜的则要将圆片边缘正反两面约200-300mm范围内的模板去除，并清除薄膜表面的杂物。[6]（5）安装上下模具，视情况加入模具垫块，对圆片的内外表面涂润滑油，涂抹范围为顶端向里200-300mm，涂抹应均匀，上下模具等都要涂匀。（6）冲压第一枚封头时，吊出封头，用样板检查断面形状，同时检查有无鼓包，以及有无减薄，并检查表面有无划伤，箍印等，如无上述异常则可以继续冲压,封头成型后，封头表面如有划伤则及时打磨，并确认最小板厚，确认是否有划伤，拉伤，曲皮，桔皮，鼓包，皱折，箍印等不良现象。（7）封头如有鼓包皱折等现象应连同工艺卡一起流转至返修工序。（8）每只封头应能看清指令号，单件号，材质，否则要重新移植，每个规格产品经检验后，随工艺卡（要签上姓名）一起转至下道工序，由下道工序确认。3.压鼓工序3.1压鼓操作压鼓工序和冲压工序是同一步骤的工序，冲压工序范围φ159-φ1900mm而压鼓工序的范围是φ1600-φ4800mm。与冲压不同的是压鼓大多只是把封头大体成型，最终成型则是由旋压完成，冲压如果不经客户的特殊要求，最终成型步骤则是不需要的。φ1600-φ1900mm的封头这两道工序则是都需要的。3.2压鼓机的构成（1）主油缸装有上模头是压鼓执行的只要部件。（2）支撑座固定下模头与上模头的中心在一条直线上。（3）支撑架Ⅰ装有滚动轮，调节圆片前后位置。（4）支撑架Ⅱ装有滚动轮，旋转圆片。除此之外，还有液压系统，电机，油泵，储油箱，以及控制台。3.3压鼓机操作步骤(1)首先承接了下料工序的流转卡后，找到对应下好的圆片。(2)对照工艺流转卡上的工艺要求，换上对应的一套模具，且用量具确定所选用的模具尺寸和要压制的圆片尺寸吻合。(3)与冲压机不同的是压鼓则不是从原片中心开始压制，而是从圆片的边缘开始，只要将模头和圆片对齐就行。(4)压制过程中是不断通过控制旋转轮的旋转带动圆片旋转，按照一定的顺序进行压制。(5)在压制完成后，用已准备好的模板进行比对。如果有偏差再进行进一步的调整。3.4压鼓作业标准（1）模具对产品质量和能否顺利压鼓成型至关重要。因此要求操作者必须根据加工情况选用适合的模具以及适时调整垫板。（2）操作者接到工艺卡后，仔细看清工艺卡，根据工艺卡核对实物，确认该实物的指令号，单件号，材质。数量，炉批号等。根据工艺卡选用模具。（3）对于EHA，EHB形状的封头采用0.82*D的标准选用，对于DHB，PSH,MD等特殊品应根据工艺卡要求选用模具，但原则上按P*0.82/1.15或P*0.82/1.2的标准选用。[1]（4）压制前须仔细检查圆片的质量，无焊缝圆片端部是否光滑，有无缺口，表面有无切割的熔渣和缺陷。（5）有焊缝的圆片除仔细检查圆片端部等缺陷外，同时须检查焊缝打磨是否高于母材，焊缝两端是否有焊接飞溅物，焊缝端部打磨是否光滑，有无裂纹缺口。（6）需两张或两张以上叠加压制时，应将每片的结合面擦拭干净，根据情况必须时，委托焊接班将圆片焊接在一起压制。（7）检测圆片的厚度（最厚，最薄，是否和工艺卡一致，测量圆片尺寸是否和工艺卡要求一致。（8）压制前必须清除内外表面一切杂物，以防有麻点出现。（9）对于一般的不锈钢材料（5mm以上的板材）则应用特氟龙板包扎上模具并将下模具表面打磨光滑（必要时下模具也要特氟龙板包扎）以确保工件表面质量，同时压制过程中要绝对避免杂物进入模具和半成品。[6]（10）压制过程中，当圆片出一定R形状时，必须用相应的R的样板测量，压制过程中应视工件的变形程度来调整压力。（11）压制完毕后，测量板厚，测量弧长。检查表面质量，检查端部及焊缝端部是否光滑（必要时打磨出礼）。（12）把检查过的半成品随工艺卡流转至下道工序（并签上操作者的姓名）由下道工序确认接受认可后方可。4.旋压工序4.1旋压操作旋压工序是压鼓后的封头成型工序，主要针对大型封头r和直边的形成。4.2旋压机的构成（1）成型轮连接相应的模具，旋压时在封头内侧，模具顶端与半成型封头R与直边相切处相切。（2）托轮同样也是连接和成型轮一样的模具，旋压时在封头外侧，与成型轮相切。（3）底座用于固定封头，且底部可以根据封头大小前后移动，封头安装时要使底座的中心与封头的中心在一条直线上。（4）中心杆用于固定封头，且中心和底座的中心在一条直线上。除此之外还有电机，电路板，连接轴，以及控制台。4.3旋压的操作步骤（1）承接压鼓工序的流转卡，根据流转卡确定要旋压的相应的封头。（2）根据封头的直径，选择相对应的上下模具。（3）装夹封头，确保封头的中心点和底座中心点在一条直线上。（4）先调节成型轮与封头相切，然后根据成型轮的位置调节托轮。（5）在旋压的过程中要观察成型轮与托轮的相对位置，且不断用模板就行比对。直到r达到要求为止。4.4旋压作业标准（1）旋压轮的材料为轴承钢或球墨铸铁，模具对产品质量和能否旋压成型密切相关，因此操作者必须根据加工情况选用合适的模具，同时，由于模具的形状及表面状况对工件的质量有很大的影响，因此，在加工前以及加工过程中必须对模具进行充分的点检。（2）根据工艺卡的要求，确认圆片，压鼓或予压后半成品的指令号，规格，材质，数量是否相符，并检查表面质量及端部有无缺陷，发现异常时及时与上道工序联络，并及时处理。（3）检查半成品的端部是否光滑，有无缺口，裂纹，表面有无切割或焊接熔渣，同时须检查焊缝打磨是否高于母材，焊缝两端是否有飞溅物，焊缝端部打磨是否光滑，有无裂纹等。[7](4)压鼓或予压后的本成品，须检查有无折边，开裂，裂纹等不利于旋压加工的缺陷。(5)工件为不锈钢时，应通过予酸洗等方法进行去污处理。(6)根据工艺卡选用模具，一般小圆弧r的尺寸要求作为内部轮的选用依据。(7)根据不同的材质，板厚及钢板的反弹情况，选用略小于圆弧r的内部轮。(8)对于特殊要求的产品，须按其形状要求设计内部轮，确认模具表面情况，做好抛光打磨处理。(9)旋压加工时，为防止造成划伤和提高加工性能，需适用润滑剂（黄油）防止加工过程中发热造成封头的表面出现热裂纹和划伤，也能延长模具的寿命。(10)旋压成型过程中，应视工件成型情况及时的进行压力调整。(11)加工成型后，应对尺寸，形状，板厚，表面质量等进行检查，确认。(12)成型的产品要随工艺卡一起流转至下道工序（在工艺卡上签上自己的姓名）由下道工序的检验员或班长检