摘要
超长中央索扣属于典型的薄壁构件,不仅铸造难度高,结构刚性差,还存在异种钢焊接及切削加工过程中易发生变形及切削振动等问题,加工难度大、质量难以符合要求。为提高超长中央索扣铸造、焊接以及加工质量,以济南凤凰桥为背景进行研究。通过铸造工艺仿真模拟铸件凝固过程,分析薄壁零件铸造时钢水流动性及铸造变形的难点。通过焊接工艺评定试验分析异种材质的可焊性。通过对切削参数的优化等措施改善薄壁件刚度差、切削振动大的加工难点。结果表明:超长中央索扣在铸造时采用将冒口设置在揽绳槽内是合理的,铸造余量能充分保证后续加工;铸钢与钢板异种材质焊接时,材料ZG20 Mn在炼钢时,将碳当量控制在0.4~0.45之间可得到理想的焊接质量;合理的切削参数和装夹方式有利于减小加工过程中的变形;粗加工时尽量去除多余的加工余量,以保证精加工时尽量少的切削;粗加工后及时人工时效,能有效去除工件内部的残余应力,保证精加工精度。
The super long central buckle is a typical thin-walled component which is difficult to perform casting with poor rigidity and machining is also difficult due to the problems such as deformation and cutting vibration in welding and cutting process of dissimilar steel,so it is difficult to ensure the quality.The research is carried out against the background of Jinan Fenghuang Bridge in order to improve the casting,welding and machining quality of super long central buckle.The difficulty of molten steel fluidity and casting deformation in thin-wall casting is analyzed by simulating casting solidification process.The weldability of dissimilar materials is analyzed by welding procedure evaluation test.By optimizing the cutting parameters and other measures,the machining difficulties of thin-walled parts with poor rigidity and large cutting vibration are improved.The result shows that(1)it is reasonable to set the riser in the rope groove when casting super long central buckle,and the casting allowance can ensure the subsequent machining;(2)when welding dissimilar materials of casting steel and steel plate,the ideal welding quality can be obtained by controlling the carbon equivalent of ZG20 Mn between 0.4 and 0.45 during steelmaking;(3)reasonable cutting parameters and clamping methods are beneficial to reduce deformation during machining;(4)it shall remove excess machining allowance as far as possible during rough machining to ensure as little cutting as possible during finish machining;(5)manual aging can effectively remove the residual stress inside the workpiece after rough machining and ensure the accuracy of finish machining.
作者
王翔
韩月鹏
陈远林
孙文波
刘春香
WANG Xiang;HAN Yue-peng;CHEN Yuan-lin;SUN Wen-bo;LIU Chun-xiang(Jinan Urban Construction Group Co.,Ltd.,Jinan Shandong 250100,China;CCCC Second Navigation Engineering Bureau Co.,Ltd.,Wuhan Hubei 430050,China;Deyang Tianyuan Heavy Industry Co.,Ltd.,Deyang Sichuan 618000,China;Shandong Yifangda Construction Project Management Co.,Ltd.,Jinan Shandong 250000,China)
出处
《公路交通科技》
CAS
CSCD
北大核心
2021年第S01期92-95,共4页
Journal of Highway and Transportation Research and Development
关键词
桥梁工程
中央索扣
薄壁件
铸造工艺
异种材质焊接工艺和机加工艺
bridge engineering
central buckle
thin wall parts
casting process
welding process and machining process of different material
