Hot and cold process G type 3TEU container flat car underframe steel structure manufacturing process .
The C3 3TEU container flat car is a special flat car designed for transporting containers on the quasi-rail line of the Australian railway network. The car has extremely high requirements on the quality of assembly welding. Its car body is all-steel welded structure, mainly composed of the chassis and its The bottom bracket consists of the middle beam assembly, the end beam assembly, the bolster beam assembly, the small cross beam, and the side beams. The middle beam assembly becomes the main load-bearing part of the car. Now the chassis structure and assembly welding process are analyzed. As shown in the following 1 midbeam manufacturing process, the beam structure sees that the center beam of the car is composed of the web, the upper cover plate of the middle beam, the lower cover plate of the middle beam, the partition plate, the impact seat, and then assembled from the plate seat and the upper core plate. It adopts a plate-assembled double-fish-belt box-shaped structure. The beam web is composed of 2 T14 and 1 T12 steel plates. The upper cover of the middle beam is spliced ​​by T16 steel plates, and the lower cover of the middle beam is spliced ​​by T20 steel plates. The separator is made of T8 steel plate. The material of each plate is Q345B or Q345E low alloy high strength structural steel (.365MPa, 520MPa). The steel castings on the middle beam, such as the upper core plate, the impact seat and the rear slave plate seat, etc. are all made of ZG230- 210B steel 1.1 middle beam structure analysis The middle beam assembly composition 1- intermediate pad; 2- bolster beam cover (middle) 3- separator beams; of 4- beam cover; 5- beams at the cover plate; beam web 6; 7- upper core plate; 8- rear seat from the plate; 9- impact seat.
1.2 Assembly process analysis The beam assembly is the key to ensuring the quality of the whole vehicle, which directly determines the length of the chassis and the assembly accuracy. For this purpose, a special center beam set that is leveled by a level is used, and a reasonable positioning reference and clamping are used. The technical requirements for the method of assembly are: the length deviation of the middle beam is * 10mm; the flatness tolerance of the lower cover plate of the middle beam at the assembly surface of the center plate is 1968-), male, engineer from Longjiang County, Heilongjiang Province, graduated from Dalian Railway in 1991 The college has a major in railway vehicles and a bachelor of engineering. Now it is engaged in technical work in vehicle technology.
1mm; the deflection of the middle beam between the two bolsters is 1,26mm; the deflection or sag of the traction beam is not more than 5mm. To meet the above requirements, some process adjustments were made before the assembly of the plates: the middle beam web is prefabricated when cutting The deflection is 32mm; when the web of the center beam is extended, the process size is adjusted to the nominal size + 18mm. Practice shows that the adjusted process size fully meets the changes in deflection and length caused by welding shrinkage. 1.3 Welding process analysis The center beam always becomes a box-shaped structure with a double fish belly. The upper and lower cover plates and the center beam web of the center beam are thicker and the overall rigidity is large. It is not easy to correct when the manufacturing process of the steel structure of the C3 type 3TEU container flat car bottom frame occurs when there are side bends and deflections. Therefore, a reasonable welding sequence is the key to ensure the assembly of the center beam.
For the requirement of 26mm upper deflection, the inner welds of the middle beam partition and the middle beam lower cover plate and the middle beam web and the middle beam lower cover plate should be welded first, and then the partition plate and the web plate should be welded on the middle beam turning machine The inner welding seam is the outer welding seam of the middle beam web and the lower cover plate of the middle beam, and the boat shape position submerged arc welding is adopted. The weld shape of the boat shape position is good and the deformation is small, so the welding seam of the upper cover plate of the middle beam and the middle beam web is also used. The plane of the upper cover plate of the welded square beam is the main positioning reference surface. Due to the large welding angle and the large amount of welding shrinkage, in order to avoid warping deformation of the upper cover plate due to welding shrinkage, the wings on both sides of the middle beam upper cover plate are prefabricated by 3mm Anti-deformation. The welding seam of the cover plate is symmetrically welded from the middle to both sides, so that the welding stress can be released. 1.4 Manufacturing process of the middle beam steel structure 1.4.1 Process flow (1) The pair of middle beams: the middle beam partition and the lower cover plate are one-to-one Group of centering beam webs, one pair of impact seats, back from the plate base-Welding the inner beam of the middle beam-Welding the middle beam web and the outer bead of the lower cover plate (2) Group welding the upper cover plate: group centering Beam upper cover 1-Welding the middle beam web and the outer bead of the upper cover plate (3) Group welded bolster beam lower cover plate (middle) Riveted upper core plate: center beam flipped 180 *-group pair of bolster beam lower cover plate (Zhong Bu Welded Pillow Beam Lower Cover Plate (Middle) and Middle Beam Lower Cover Plate 1-Milling Rivet Holes 1-Riveting Upper Center Plate 1.4.2 Process (1) Hang the Middle Beam Lower Cover Plate to the Middle Beam Set Fixture Locate and clamp by the stop block (3) Group of centering beam webs (use a horizontal ruler to detect the difference in height between the two webs, no more than 1mm allowed). From the plate seat, impact seat, and middle pad. Weld the center beam web Fillet welds for slabs, middle beam partitions and middle beam lower cover plates, welding impact seats with middle beam web welds and fillet welds on the middle beam web side, welding impact seats with middle beam web side welds, Ran Flip 180 * to weld the corner bead of the lower beam of the middle beam of the other side of the weld bead, and then flip 90 *, weld the other side of the bead (6) and hang the middle beam to the upper cover plate position of the centering beam. Fillet welds between the mid-beam upper cover plate and the mid-beam upper cover plate, and then flip 90 * to weld the other side bead.
(8) The center beam is lifted to the position of the group of centering beam upper cover plate, the group is aligned with the bolster beam cover plate (middle), after welding the bolster beam cover plate (middle) and the upper cover plate weld (9) after milling the rivet hole of the core disc From the rivet hole of the plate base, riveting the upper core plate, and then from the plate base (10) on the center beam correction table, use flame to correct the twist of the center beam, the upward deflection and the sag of the traction beam.
1.4.3 Welding method Due to the different welding angles of the welds on the inside of the middle beam, the J506 electrode with 04 claws (current 200-240 people) and 05 claws (current 240-280A) are used for manual arc welding and welding equipment. For the welding seam of the middle beam partition and the middle beam web of the AC arc welding machine, the gas shield welding of 01.2mm H08A welding wire is used, and the welding equipment is the middle beam web and the upper and lower cover plates of the gas shielded welding machine YB-500KPVTA. The outer welding seam is made of 03mm (current 480 ~ 500A) H10Mn2 welding wire, submerged arc welding at the ship-shaped position, the welding equipment is MZi-1000 submerged arc welding machine 2 chassis steel structure manufacturing process 2.1 main technical requirements 10mm, width deviation ± 5mm , The deviation of the center distance between the two center plates is ± 8mm, and the diagonal difference of the chassis is not more than 12mm (2) Install the spin lock seat for container shipment on the chassis. After the spin lock seat is assembled, the height difference between the upper planes of any four spin lock seats with a length of 6096mm on the base frame is not more than 4mm, and the height difference of the long container is not more than 6mm. Any spin lock seat in the same section The (28t 2) mm requirement should be ensured between the upper plane and the upper plane of the center beam, allowing adjustment of the thickness of the adjustment plate below the spin lock seat.
2.2 Technological process (1) Hang the center beam assembly to the base frame assembly welding fixture, see the locking hook of the fixture to lock the lower wing surface of the traction beam at both ends, so that the upper core plate and the support seat are closely adhered (2 Lift the end beam, bolster beam, cross beam, and small cross beam in turn on the pairing fixture, adjust the height and vertical and horizontal distances of each beam and the upper cover plate of the middle beam, and meet the requirements after positioning welding.
(4) Hang the base frame to the base frame turning position for the first time welding, welding each beam web and middle beam web.
(5) Transport the underframe that has been welded once to the underframe adjustment platform to detect the deflection of the center beam, the sag of the traction beam and the height difference of the ends of the ends, pillows and beams relative to the upper cover plate of the center beam, and flame correction If the size is up to standard (6), the upper cover plates of each beam are welded twice, and each upper cover plate is welded to the middle beam web, the welding seam of the middle beam upper cover plate, and between the emergency traction seat and the end beam web. Welding seam, and welding on the side bearing cold and hot process (7) Group the end beam and cross beam lock seat, adjust the vertical and horizontal dimensions and the height of the upper surface of the lock seat and the upper surface of the middle beam upper cover plate to the size requirements (9) The welding seam (10) between the welding lock seat and the end beam and the cross beam performs the second turn welding of the lower side beam and the pedal (11), and the (8) measurement of the welding lock seat and the end beam cross beam is adjusted between the lock seat Diagonal difference, positioning welding after meeting the tolerance requirements, grouping the welding holes of the attachments of the chassis, forming welding seams between the pedal plate and the end beam, etc., and welding the chassis attachment welding fixture 1-air cylinder ; 2-positioning sample; 3-positioning platform; 4-top wire; 5-steel frame.
2.3 Detection method The reasonable and accurate measurement method is the key to ensure the overall assembly of the car. Based on the above requirements for the lock seat, a detection platform and a pair of end beams and beam wires of the test sample group are provided on both sides of the tooling of the underframe group. Measure the height difference at the intersection of the two steel wires. The height difference of the lock seat of a 20-foot container is less than 2mm, and the height difference of the lock seat of a 40-foot container is less than 3mm. Through this detection method, the sample block is guaranteed when the assembly of the twist lock seat is required. Put it on the testing platform to adjust the height of the jacking wire, measure the flatness of the top plane of the end beam assembly and the cross beam assembly with the top plane of the sample block with a level meter, and then put the test sample block on the lock seat and pull it diagonally The steel structure of the steel C3 3TEU container flat car chassis is manufactured according to the above-mentioned process method. It has been proved by mass production and operation tests that it fully meets the technical conditions and performance requirements of the drawings (continued from page 13). It can reach 600 ~ 700C. The heating area is determined according to the size of the deformation. 5 issues that should be paid attention to during the assembly work. The assembly work is a more important assembly of a ring steel structure in the manufacture of H-shaped steel structures. Assembly work, must ensure perpendicularity, and flatness of the end faces. It is easy to overlook in the assembly is the staggered welding problem of the cover plate welding seam and the web plate welding seam. Because many cover plates and webs are splicing materials, they must be staggered by more than 600mm from each other, and some prohibited areas such as drilling In the area of ​​tack welding, in order to form the post-process automatic welding and safety problems during lifting, the tack welding should be made as long as possible.
Assembling small pieces is also a more important process in the manufacture of steel structures, because the holes in the small pieces are used for connecting bolts during the assembly of the steel structure. Once the tolerances of the small pieces are out of tolerance, it is difficult to assemble. Moreover, during assembly, if the hole distance is too poor, gas welding and electric welding cannot be used, and only manual filing can be used. Therefore, the most important thing when assembling small parts is to ensure the distance of the assembly holes
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