Forward skate assembly-welding section

Contents

Summary

The purpose of the diploma project is to develop a technological process for the production of forward skates, to design a section of the assembly-welding for the manufacture of skates.

The project proposes reasonable technical solutions for making skates using mechanized welding under a flux layer and manual arc welding.

The project details the selection of both welding and basic materials, welding methods, methods of quality control of welded joints, assembly and welding equipment, measures to ensure labor safety and public protection in emergency situations, energy and resource saving measures.

The project contains calculations of the thickness of the walls of the cross section of the skate, welded joints for strength, welding modes, basic technical and economic indicators, parameters of the civil defense shelter. Also in the diploma project developed a specialized tooling for assembling the welding of skates

Working drawings and process of assembly of skate welding have been developed.

The main requirements for materials, manufacture, edge preparation, assembly, welding and inspection of welded joints during manufacture are made in accordance with the regulatory and technical documents.

The proposed technical solutions made it possible to manufacture conks with maximum quality and minimum labor intensity and energy costs.

The project contains:

text documents on 229 sheets, including tables 85, figures-71.

graphic documents on 11 sheets of A1 format.

Introduction

The leading place in mechanical engineering is occupied by welding production. Many units and parts, which are part of manufactured products, machines and equipment and are obtained by casting, stamping, forging, cutting, are combined with each other using welding processes.

The high efficiency of the welding process, the good quality of the welded joints and the economical use of metal contribute to the fact that the welding technique has become the leading technological process in the manufacture of metal structures of all types.

The theme of this diploma project is: "Section of assembly and welding of forward skates Amkador 268201 in the conditions of OJSC Meter. The work examines one of the possible technologies for producing a skate.

This conic is used to manufacture the forward Amkador 268201. The forward works under difficult conditions, is exposed to dirt, water, negative temperatures and high dynamic loads.

The basic technological process was developed by the Amkador OJSC plant under the conditions of production of Metering OJSC.

The purpose of this diploma project is to increase the productivity, quality of production and mechanization and automation of welding processes for the manufacture of tank walls, namely, welding of longitudinal and annular seams. The design is carried out taking into account the current trend and recent achievements in the field of construction of tanks and technological equipment, aimed at improving their operational and environmental safety.

To accomplish this task, appropriate benches and manufacturing technology have been developed, namely, assembly and welding methods have been selected, welding materials necessary to provide the required properties of welds and joints have been specified, measures are provided to ensure the manufacture of a welded structure with a given degree of accuracy, and an assembly and welding sequence has been determined in which welding strains and stresses will not adversely affect strength.

The quality of the design of the technological process for the manufacture of welded structures mainly determines their technical and economic indicators, such as reliability, cost-effectiveness in production and operation. In the design of the manufacturing technology, the operations of the blank, assembly, welding and quality control of the finished product are comprehensively developed. The rational design of the technology should ensure the manufacture of the product with minimum labor intensity of operations, minimum consumption of welding materials and electricity, with high quality of welded joints, with the least residual deformation of the structure and with full compliance with safety measures.

Basic Materials

Material Requirements

Steels with a set of strength and service properties are used to manufacture structures operating at dynamic loads at normal temperatures. For the production of conic, it is necessary to use structural material that maintains the required level of properties, at working temperatures and loads. It must have sufficient strength, good weldability and relatively low cost.

Product Process Analysis

Shape of welded elements

When designing, the dimensions and shape of the welded elements from the position of their processability should be chosen based on the use of high-performance automatic welding methods; performing welding in a lower position; free access to the front and root parts of the seam; heating (or cooling) and subsequent thermal or mechanical treatment, if necessary; minimizing weld lengths and mass of base and build-up metals, etc.

In this case, sheet metal is used as billets for the beam. It is more advisable to use shaped rolled stock. This will reduce the length of the seams by 2 times, and therefore reduce welding strains and stresses, as well as reduce the manufacturing time of the beam.

Energy saving

Demand for energy resources is constantly growing, while tariffs on them are rising, mineral reserves (oil, gas, coal) are declining, the country's ecology is deteriorating - all this attaches special importance to energy conservation. Many countries are developing and implementing energy efficiency programmes.

One of the reasons for the energy saving event at the enterprise is to reduce costs and increase economic efficiency in production. At the moment, in industrial enterprises, the percentage of energy costs in costs is 912%, and this percentage is constantly growing. This problem is mainly related to the physical and moral wear of equipment, as well as large losses of energy resources arise during transportation.

The energy-saving path in the development of Belarus is allowed only in the implementation of the formation and application of energy-saving programs and measures in enterprises and industries. It is necessary to establish the most rational use and use of energy resources in industrial enterprises. The postponement of energy conservation measures at the enterprise can (and as a result - will) lead to significant economic damage to the enterprise itself and a negative impact on the environment.

If this process is not stopped, the increase in costs, accompanied by financial losses, will delay the renewal of the production base of the enterprise, which is necessary for the development of production. In order to prevent this process, it is necessary not only to carry out energy conservation activities in the enterprise, but also to constantly develop, update and improve energy audit methods, evaluate the effectiveness and quality of energy conservation programs, it is necessary that these programs take into account the multivariability of the use of investment sources that are intended for their implementation.

These measures will help reduce energy consumption and costs, which will allow you to purchase additional funds with which it will be possible to ensure the production of technological equipment upgrades. In order to achieve such an outcome, the following measures must be taken:

Implement a comprehensive survey of the enterprise.

Get recommendations of specialists on the configuration and necessary equipment of the enterprise with modern equipment for energy saving.

Develop a comprehensive energy saving program for the enterprise.

Then implement all program measures for energy saving at the enterprise.

Principles of energy saving

Of all the changes that are observed in real isolated systems, those that contribute to reducing the intensity of entropy increase (limiting the rate of energy degradation) should be used first.

- Providing in any isolated system a state with minimal production of entropy and there is an energy-saving principle of functioning of this system.

- The principle of the maximum possible preservation of the system structure in a non-equilibrium state is one of the conditions for energy-saving development of this system.

- Energy-saving activities include the following main areas (according to the number of types of entropy):

measures to reduce the degradation of any energy associated with their conversion to thermal energy;

implementation of measures that contribute to an increase in the streamlining of the structure of any systems. The defining goal here is the formation of a sustainable society that takes into account the interests of future generations;

the exchange of information between individual parts in any system (and in society as a whole) should contribute to the accumulation of non-entropy (negative entropy), albeit due to an increase in energy consumption.

Conclusion

The shortcomings of the basic manufacturing technology were analyzed and a new version was developed on the basis of the analysis.

Taking into account the processability of the design and regulatory documents, steel grades 09G2S, St3 ps and Steel 20 were justified and selected as materials for the construction.

It is shown that the developed manufacturing technology can be implemented using modern existing equipment for assembly and welding. A reasonable selection of modern assembly and welding equipment was made.

Welding mode parameters are calculated to ensure high technological strength of welded joints

Taking into account the requirements of the regulatory and technical documents and the production experience of AAO "Meter," the optimal forms of edge preparation, welding materials were chosen that ensure high quality of welded joints, the operability of the structure at low temperatures, the possibility of using existing equipment and availability for non-destructive testing.

In accordance with the requirements of regulatory documents, the selection of methods for monitoring the welded joints of skates was made.

Reasonable selection of assembly and welding equipment was made.

The validity of engineering solutions selected in the diploma project is confirmed by economic calculation .

Taking into account the norms of technological design, norms and rules of life safety, a section for the assembly and condenser of surface cooling was designed, providing a direct-flow, irretrievable direction of cargo flow.