Development of process of assembly-welding of DU-1000 reverse gate housing

Contents

CONTENTS

Paper

INTRODUCTION

1. PROCESS SECTION

1.1. Analytical Overview

1.2. Patent search

1.3. Purpose and features of reverse gate design

1.4. Justification of article material selection

1.5. Justification and selection of welding method

1.6. Electrode wire for welding

1.7. Equipment selection

1.8. Selection of protective gas

1.9. Calculation of welding modes

1.10. Gate Assembly-Welding Process

1.11. Quality control of welded joints

2. DESIGN SECTION

2.1. Assembly and welding equipment

2.2. Strength calculation of welded joints

2.3. Design Load Calculation

2.4. Product Assembly-Welding Area Layout Development

3. Economic section

3.1. Technical and economic analysis of modern assembly and welding equipment

3.2. Calculation of economic efficiency of assembly-welding processes

3.3. Calculation of technical time standards

4. SAFETY OF LIFE OF PROCESS PROCESSES OF ASSEMBLY-WELDING OF VALVES LOCKING

4.1. Analysis of hazardous and harmful factors during assembly and welding of the back gate housing

4.2. Development of engineering solutions to reduce the impact of identified hazardous and harmful factors on workers and the environment

CONCLUSION

LIST OF SOURCES USED

APPLICATION

APPLICATION

Paper

The explanatory note contains: 118 sheets, 18 figures, 29 tables, 64 literary sources. The graphic part contains 11 sheets of A1 format, 2 sheets of A2 format, 4 sheets of A3 format, 2 sheets of A4 format.

Keywords: BACK GATE HOUSING, DU1000, SEMI-AUTOMATIC WELDING, WELDING MODES, WELDING MATERIALS, WELDING RECTIFIER, ROTATOR.

The purpose of the work is the development of a technology for assembling and welding the body of the reverse DN1000 gate in a CO2 environment.

In this exhaust qualification work, the choice of welding method is justified and the technology of assembling and welding the housing of the reverse DC1000 gate, which is an element of the pipeline and is used to provide flow relief in the event of a sharp increase in pressure or other parameters in the system, is developed. The selection of welding materials and equipment for welding operations was carried out, welding modes were calculated, the technological process of assembly and welding operations was developed.

In the economic part of the work, the selected welding method was analyzed, the cost-effectiveness of implementing the developed technology was evaluated.

In the section on labor protection, labor protection measures were developed during welding and fire safety.

Summary

The purpose of the work is to develop the technology of assembly-welding of the inverse DU1000 brew body with the introduction of more modern equipment and the replacement of manual arc welding under the flux layer with semi-automatic one in CO2.

In this final qualification work, the choice of the method of assembly and welding of the gate housing of the reverse DC1000 is justified, the selection of welding materials and equipment for welding operations was made, the welding modes were calculated, the technological process of assembly and welding operations was developed. In the economic part of the work, the selected welding method was analyzed, the cost-effectiveness of implementing the developed technology was evaluated. In the section on labor protection, labor protection measures were developed during welding and fire safety.

Introduction

The history of welding originates from the discovery of an electric arc in 1802. Professor of Physics V.V. Petrov, who suggested that this phenomenon could have practical meaning, which he realized in 1881. Russian inventor N.N. Bernados, who used an electric arc to connect steel using an additive wire. Subsequently, such welding was used on the railway during the repair of rolling stock. [1]

A little later, in 1888, the Russian engineer N.G. Slavyanov improved the welding technology by proposing the use of an electric arc with a melting metal electrode. He also used flux to protect the metal of the welding bath from air and manufactured a welding generator of his own design, and also organized the world's first electric welding workshop.

Nevertheless, in the pre-revolutionary period, welding was not widely used in Russia. Welding became widespread only in the 1920s at various industrial enterprises. Then more and more advanced welding machines began to appear thanks to the development of such Soviet scientists as V.P. Nikitin, D.A. Dulchevsky, K.M. Novozhilov, G.Z. Voloshkevich, K.V. Lyubavsky, E.O. Patonov, some of whom even won state awards for their work in the development of this area. Welding made the country's industry more economically profitable, since it could replace expensive and labor-intensive processes, such as riveting or casting, metal costs, equipment costs were also reduced, and the possibility of automation and mechanization of welding work also played a role.

Nowadays, welding is used in the manufacture of many structures, including pipe fittings.

A person began to use pipeline valves a long time ago. According to historians, in 5000 BC, people built simple pipeline systems on which there were valves and cranes.

But the Roman Empire proved the existence of reinforcement in ancient times. Archaeologists studying this culture found a cork crane at the excavation. With this device, the Romans opened and closed the water. The crane is cast from bronze.

The history of the creation of industrial pipeline valves began in the 19th century. This is the time of the first development of steam engines, the designs of which required a device that could block the flow of hot steam through the pipes.

The first notable steps in industrial reinforcement construction belong to Timothy Hackworth and Joseph Hopkinson, who developed the world's first wedge gate valve.

For Russia, industrial reinforcement construction has become possible thanks to the work of a foreign industrialist named Gros. He founded a foundry (1878) in St. Petersburg, which was engaged in the serial production of valves. And after 10 years, the company was bought by a German. The company was called JSC Langenzipen and Co. In the future, under this name, several more plants will open throughout Russia, which will begin mass production of valves for boiler houses and fire departments, fire cranes, pumps, pressure gauges and copper pipes.

After nationalization, in 1922 the Lagenzipen plant was renamed the Petrograd Reinforcement Plant "Banner of Labor." It was from this moment that the history of Soviet, and now Russian reinforcement construction began.

Process Section

THE PURPOSE OF THE WORK is to develop the process of assembly-welding of the gate body of the reverse DN1000, substantiation and selection of the article material, welding materials, welding method, equipment, identification of design shortcomings.

OBJECT OF WORK INVESTIGATION - process of assembly-welding of DC1000 reverse gate housing.

SUBJECT OF INVESTIGATION - welding with a melting electrode (wire) in the medium of carbon dioxide (CO2), the body of the gate of the reverse DN1000.

1.1. Analytical Overview

RELEVANCE. Improving the efficiency and quality of manufactured metal products is an urgent task today. One of the ways to solve it can be distinguished by the development and implementation of technological processes and equipment that meet modern requirements.

Isolation valves - a type of pipeline valves designed to block the flow of working medium with a certain tightness. The main difference between industrial valves and plumbing is the performance of a pipeline in which instruments are used. Large pipe diameters require overall devices. Also, the presence of high temperature and pressure determines the structural features. About 80% of valves in industry come from shut-off devices. These are shut-off valves, cranes, latches, rotary locks.

SCIENTIFIC NOVELTY OF THE Bachelor's STUDY:

1. Theoretically justified and confirmed the fundamental possibility of using a new type of welding.

2. The design of the rear shutter housing DN1000 was improved.

PRACTICAL RELEVANCE.

1. The applied significance of the results is the possibility of using the results of the study to improve the application of the reverse DC1000 shutter housing.

2. Estimated annual economic effect for the enterprise in comparison of basic (old) and projected (new) types of welding

. Economic section

3.1. Technical and economic analysis of modern assembly and welding equipment

Mechanization and automation of welding production is an important means of increasing labor productivity, improving the quality of welded products and improving working conditions.

Currently, it is not easy to find the means to replace and modernize obsolete machines and units, but the growth of scientific and technological progress and competition leaves no other choice. Therefore, the volume of production of specialized welding and auxiliary equipment for general purposes is increasing. Including equipped with software control systems, the creation of new technological processes and progressive means of small mechanization, which, in combination with the main welding equipment, would provide integrated mechanization of the production process, increase productivity and improve working conditions.

At the same time, a system of universal assembly devices has been widely used, based on the principle of aggregation - the repeated use of a certain set of standard parts and assemblies, from which a variety of devices are assembled over several hours. [59]

The creation and implementation of readjustable equipment reduces the cost and time for preparing production by 3-5 times, which contributes to the rapid commissioning of new industrial models of machines.

The most "bottleneck" in the process of manufacturing welded structures are assembly and auxiliary operations, including:

during assembly - installation, fixation and fixation of parts and assemblies;

during welding - installation and rotation of articles, installation and withdrawal of welding machine.

These operations cost an average of 35% of the labour input of all welding operations.

Conclusion

In this work, a thorough study of the technology of assembly-welding of the rear gate housing DN1000 was carried out based on the initial data (drawing, technical requirements). Requirements for reliability, service life of the structure, approach to selection of welding material were analyzed in order to ensure high strength of welds, methods of obtaining non-detachable joints were selected. The necessary welding equipment, as well as welding modes, methods of inspection of welded joints are considered.

Welding under flux layer is replaced with semi-automatic welding in protective gas medium. This saves money, because the flux is replaced with less expensive carbon dioxide, while reducing electricity consumption, therefore reducing the cost of the housing.

The proposed technology of welding production of the rear gate housing provides cost-effective and reliable quality of welds, which allows recommending it for wide implementation in production.