【摘要】：焊劑片約束電弧超窄間隙焊接方法經(jīng)過不斷地發(fā)展已經(jīng)取得許多階段性成果。目前該技術(shù)主要研究的問題是:(1)如何實現(xiàn)焊劑片及焊劑片鏈的自動化生產(chǎn);(2)如何穩(wěn)定地將焊劑片鏈輸送到坡口中完成穩(wěn)定的焊接過程,獲得性能良好的焊接接頭。本文在總結(jié)以往焊劑帶(焊劑片鏈)制作工藝和適用性能優(yōu)缺點的基礎(chǔ)上,重新設(shè)計了焊劑片的結(jié)構(gòu)并通過壓片法制備出所設(shè)計的焊劑片。為了解決單個的焊劑片容易繞著玻璃纖維線旋轉(zhuǎn)的問題,本文提出了玻璃纖維網(wǎng)式焊劑片鏈,這種結(jié)構(gòu)的焊劑片鏈不僅保留了玻璃纖維線式焊劑片鏈的優(yōu)點而且具有很好的彈性。當焊劑片鏈被輸送到坡口中時,焊劑片鏈能夠緊貼坡口兩側(cè)壁,從而保證焊后坡口兩側(cè)壁和根部熔合良好。為了編織本文設(shè)計的玻璃纖維網(wǎng),作者制作了一套簡單的玻璃纖維網(wǎng)編織機;同時對玻璃纖維網(wǎng)粘結(jié)劑的配比進行了探究,試驗發(fā)現(xiàn)環(huán)氧樹脂與稀釋劑的配比為1:2時,涂敷粘結(jié)劑后玻璃纖維網(wǎng)不僅具有較好的彈性,而且玻璃纖維網(wǎng)對折時不易斷裂。為了實現(xiàn)自動化超窄間隙焊接,作者設(shè)計了一套四自由度超窄間隙焊接實驗裝置。此套裝置由送置焊劑片鏈超窄間隙焊接專用焊槍、焊接工裝夾具、焊接實驗裝置行走機構(gòu)組成。送置焊劑片鏈超窄間隙焊接專用焊槍不僅能夠?qū)崿F(xiàn)焊劑片鏈的自動輸送,而且焊槍的送絲導(dǎo)電部分采用了一體化設(shè)計,大大減少了焊槍零部件的個數(shù),便于焊槍的裝配和拆卸。焊接工裝夾具由四條方形鋼連接而成,利用加力螺栓和兩個定位螺栓對焊接試樣進行裝夾定位。焊接實驗裝置行走機構(gòu)具有四個自由度,能夠沿著X軸、Y軸、Z軸移動和繞著Z軸旋轉(zhuǎn)。最后,利用作者制作的超窄間隙焊接實驗裝置進行工藝試驗;本文分別從下降外特性電源、焊絲偏移量、坡口寬度變化量三個方面探究其對超窄間隙焊接工藝穩(wěn)定性的影響。在相同焊接工藝參數(shù)下,通過對比下降外特性電源和平特性電源模式下焊接試樣的焊縫橫截面形貌和焊接過程波形的變化,發(fā)現(xiàn)下降外特性電源能夠增加電弧的穩(wěn)定性,對超窄間隙焊接具有更好的適應(yīng)性。以往的焊接工藝試驗已經(jīng)證實焊絲與焊劑片之間的距離對約束電弧、焊縫成形起著至關(guān)重要的作用,而且兩者之間的距離為0.35~0.5mm時焊縫成形質(zhì)量最好。本文通過玻璃纖維網(wǎng)縱向線的直徑控制焊絲與焊劑片之間的距離,當焊絲偏離坡口中心線時,焊絲與玻璃纖維網(wǎng)的縱向線之間將會產(chǎn)生力的作用,從而造成焊絲端頭產(chǎn)生微量的變形,保證焊絲端頭與焊劑片之間有足夠的距離,從而保證坡口側(cè)壁和根部熔合。實際工業(yè)生產(chǎn)中同一條焊道上的坡口寬度會產(chǎn)生一定量的變化,本文通過一定焊接工藝參數(shù)下焊接V形焊道試樣模擬這一現(xiàn)象。試驗發(fā)現(xiàn):隨著坡口寬度的增加,熔滴過渡頻率減小,焊接電流和電弧電壓的波動性增大。
[Abstract]:Flux-confined arc ultra-narrow gap welding method has been continuously developed and achieved a lot of achievements. At present, the main problems of this technology are as follows: (1) how to realize the automatic production of flux sheet and flux chain; (2) how to transport the flux chain steadily to the groove to complete the stable welding process and obtain the welding joint with good performance. On the basis of summarizing the advantages and disadvantages of the manufacturing technology and the applicable properties of the flux strip (flux chain), the structure of the flux sheet was redesigned and the designed flux sheet was prepared by pressing the flux strip. In order to solve the problem that a single flux sheet rotates easily around the glass fiber line, a glass fiber mesh flux chain is proposed in this paper. This kind of flux chain not only retains the advantages of glass fiber wire flux chain, but also has good elasticity. When the flux chain is transported to the groove, the flux chain can close to the two sides of the groove, so as to ensure a good fusion between the two sides of the groove and the root after welding. In order to weave the glass fiber mesh designed in this paper, the author made a simple glass fiber mesh knitting machine, and studied the proportion of the glass fiber mesh binder, and found that the ratio of epoxy resin and diluent was 1:2. After coated with binder, glass fiber mesh not only has good elasticity, but also is not easy to break in half fold. In order to realize automatic ultra narrow gap welding, the author designed a four-degree of freedom ultra narrow gap welding experimental device. The device is composed of welding torch, welding fixture and walking mechanism of welding experiment device. The welding torch for ultra-narrow gap welding of flux chain can not only realize the automatic conveying of flux chain, but also adopt the integrated design of wire feeding conductive part of welding torch, which greatly reduces the number of welding torch parts and facilitates the assembly and disassembly of welding torch. The welding fixture is made of four square steel. The welding specimen is clamped by adding bolt and two positioning bolts. The walking mechanism of the welding experimental device has four degrees of freedom and can move and rotate around the Z axis along the X axis and Y axis. Finally, the process test is carried out by using the ultra-narrow gap welding experimental device made by the author, and the influence of this device on the stability of the ultra-narrow gap welding process is explored from three aspects: the power supply with descending external characteristics, the wire offset and the change of the groove width, respectively. Under the same welding process parameters, by comparing the shape of weld cross section and the variation of welding process waveform of welding sample in the mode of decreasing external characteristic power supply and characteristic power supply, it is found that the drop external characteristic power supply can increase the stability of arc. It has better adaptability to ultra narrow gap welding. Previous welding process tests have proved that the distance between wire and flux sheet plays an important role in arc restraint and weld formation, and the quality of weld formation is the best when the distance between the two is 0.35~0.5mm. In this paper, the distance between the wire and the flux sheet is controlled by the diameter of the longitudinal line of the glass fiber mesh. When the wire deviates from the central line of the groove, the force between the wire and the longitudinal line of the glass fiber mesh will be produced. Thus the wire end is deformed and the distance between the end of the wire and the flux sheet is enough to ensure the fusion of the side wall and the root of the groove. The width of the groove on the same welding pass will change in a certain amount in the actual industrial production. This paper simulates this phenomenon through the welding V-shaped welding specimen under certain welding process parameters. It is found that the droplet transfer frequency decreases and the welding current and arc voltage fluctuate with the increase of the groove width.
【學(xué)位授予單位】：蘭州理工大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2017
【分類號】：TG44

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