沈阳工业大学化工装备学院毕业设计（论文）外文翻译毕业设计（论文）题目：含硫氨污水冷却器外文题目：Head processing technology译文题目：封头加工工艺院（系）：化工装备学院专业班级：过控0802班学生姓名：孙鹏博指导教师：闫小波2012年3月11日Head processing technology1.welding process1.1welding operationOur factory common welding methods are: manual welding, argon arc welding, submerged arc welding.(1) manual welding is mainly used for carbon steel 3-6mm plate welding.(2) submerged arc welding to more than 8mm carbon steel stainless steel sheet welding mainly.(3)3-6mm stainless steel argon arc welding with welding mainly. Commonly used stainless steel wire ER304and ER316L steel wire, commonly used to J422and J507and J426and J427low-temperature welding consumables. Flux of carbon steel used is the HJ431, stainless steel commonly used is HJ260,.As a result of welding wire flux can be easily affected with damp, stored in the infrared drying machine, flux HJ431and HJ260drying temperature is 250-300℃. Welding wire J422and J350drying temperature were 150℃ and 300 ℃Welding process is completely in accordance with the" welding" execution, sheet thickness determines the welding to welding or double sided arc welding in welding, after the weld seam inspection ( RT X ray ) judgment without pores, cracks and other defects, such as found in the above deficiencies, to the repair, until the filming.1.2 welding operation standard(1) welding procedure card after receiving process, affirm the process card and physical material, quantity, unit number, specifications, size instruction number is consistent, whether there is debris around the wafer, wafer splashes whether clean removal, such as treatment is not clean, will use the grinding clean.(2) there is no welding test plate, groove cutting quality can meet the requirement, material surface without obvious defects, such as abnormal response.(3) according to the" Regulations" welding procedure card check of welding groove type and dimensions correspond to.(4) on each side of groove surface grinding, butt edge offset is not greater than the10% thickness, and not more than1.5mm.(5) point fixed the first weld layer terminal welding length not less than 50mm, arc board specifications should be 150*150mm and a mask having R arc, team rounds should be given within 8 hours of welding, or to use flame to the moisture inside the baking groove.(6) the welder holds" welding" and" welding records" for welding consumables, welding two class library for registration, using flux field volume should not exceed 4 hours, or to continue to back into the oven drying.(7) a, preheating plate thickness not less than 30mm carbon steel, low alloy steel, the preheating temperature of welding process by" card"," standard" provisions of the welding technology.B, preheating range width not less than 4mm and no less than 100mm. C, in the process of welding groove at any time temperature shall not be less than the prescribed temperature.D, when welding temperature is below 0 ℃( arbitrary thickness) must be heated to 15 ℃or above in order to welding.(8) a before welding, welding to welding equipment inspection, examination was normal before welding facilities.According to B,"" the requirements of welding process welding, welding and fill in the recordsC, welding, welding layers shall be in accordance with" welding" requirements, welding shall not be a large current, less layers. (9) removal of the root a, stainless steel cleaning before the root groove sides, within the range of 300mm, splashing paint coating.B, using carbon arc air gouging, should be selected according to the request carbon rod diameter.C, root cleaning, grinding cleaning groove and two side the existence of carburized layer, oxide, slag and other sundries. Grinding width: manual welding, rust, oxide above 20mm, oil30mm above, automatic welding, rust, grease, oxides 25mm50mm groove inner grinding requirements, carbon steel, low alloy steelδn ≤10mm weld, its two ends within the range of 300mm carburized layer must be completely removed, the rest part allows the removal of more than 50%. Other non-ferrous metals must be completely clear. [3]D, root cleaning, composite steel Cr-Mo, manual welding and the thicknessofδn ≥30mm welds shall be examined by PT.(10) during the process of welding defect repair by welding repair welding repair monitor instruction experienced welders as. Repair welding process should eliminate soldering phenomenon, or polished after welding, the following defects must be removed before welding to welding crack,①partial②③pits the stomaA shall not be lower than the parent material, weld.B, there shall be no undercutting.C, without removing the residual high seam. The surface shall not have cracks, pores, crater, undercut and slag inclusions, and may not retain the slag and spatter.D, removal of residual high weld inspection shall not have any defect display PT.E, such as the defects of carbon steel, low-alloy steel repair procedures: a grinding wheel or a carbon arc gouging polishing cleaning→ PT check grinder grinding out the welding groove, welding, PT, stainless steel repair procedures: a grinding wheel or a carbon arc gouging polishing cleaning→PT (δ n≥ 2mm need )→grinder polished to a welding groove welding→ PT examination. [4](12) welded internal rework, repair procedures: location of defect, defect removal→ PT→→removal check welding weld→ PT examination. [5] (13) according to RT film, RT staff and the welders in welding seam together determine the location of defects, including the following requirements when using UT to determine the defect position, the first repairδ n≥ 30mm use UT to determine the location of defects, two or three repairδ n≥ 20mm using UT to determine the defect position, UT positioning by RT after class. The position and depth of defect ( calibration side shall be the depth of defect≤1/2 side).(14) after the welding inspector or monitor by confirmed, in the process card signed your name and object together with transfer to the next process, by the next process responsibility recognition can.2.stamping process2.1stamping operationStamping operation is small head forming an important operation. The same stamping is also head of the cracking, thinning appeared most processsection.2.2punching machine.(1) the master cylinder is mainly used to connect the die head, is the head forming the necessary parts.(2) side cylinder used for pressing die ring, fixing the upper and lower mold ring of head disk. The head in the pressing process is to prevent the crease, as an important part of the drum kit.(3) the overflow valve used for controlling the compressor overall pressure, prevent the wafer during the pressing process of tears. (4) stamping valve in pressure, stamping valve on pressure relief, achieve average pressure effect.In addition, circuit boards, motors, circuit boards, storage tank, operation platform, pedestal are stamping machine components.2.3.3 stamping operation steps(1) first of all to undertake a blanking process card, find a good wafer.(2) the control process card on the technological requirements, put ona set of corresponding die, and with the use of gauges to determine the selected die size and to suppress the wafer size.(3) the wafer is clamped on the upper and lower mold inside the circle, and determine the die head of the center point and the center point of the wafer in a straight line.(4) the operation ring mold and die relative motion, pressure test, according to the control rod rebound to judge the size of the pressure, thereby regulating pressure size.(5) pressure test end, pressed wafer, stamping.2.3the stamping operation standard(1) the control task orders, confirm physical and process card is consistent, according to the process card confirming workpiece number, material, specification, batch number and other factors, at the same time check wafer end there is no crack, burr, polished wafer whether it meets the requirements, whether chamfer, is facing the good, there are special requirements when the problem is found, in time to contact.(2) according to the process card correct selection of die mold surface, inspection, found bruises and serious injury must be polished, but must be clean mold surface corrosion and dirt.(3) according to the technology card size, shape, texture, straight edge higher to suppress.(4) the warm-stamping ( according to requirement sheet property is heated to a certain temperature, and then stamping process ), to prepare a baking gun, gas, oxygen, percussion with head shall prepare the corresponding template, double-sided film to the wafer edge of both sides in a range of about 200-300mm template removal, and clear the film surface. [6] (5) mounted on the lower die, as the case to join the die pad, the wafer inside and outside surface coated with oil, applied range of top to200-300mm, smear should be uniform, the upper and lower mold are evenly coated.(6) the first gold stamping head, hanging out with a model head, check section shape, at the same time, check whether the drum kit, and there is no thinning, and check the surface has no scratch, hoop printing, such as none of the above abnormalities can continue to stamping, head forming, sealing surfaces such as scratches are timely grinding, and confirm the minimum board thickness, confirm whether a scratch, strain, curved peel, orange peel, drum kits, wrinkle, hoop printing etc..(7) such as a head drum kit fold phenomenon should be together with the card with the move to rework process technology.(8) each head should be able to see the instruction, piece number, material, or to transplantation, each product specifications after testing, the process card ( to sign the name ) together to the next process, by the next process validation.3.pressure drum process3.1pressure drum operationPressure drum process and stamping processes are the same steps in the process, stamping process range of φ 159- φ1900mm and pressure drum process is in the range of φ 1600- φ4800mm. And stamping is different pressure drum mostly the head generally forming, eventually forming is completed by spinning, stamping without the special requirements of customers, eventually forming step is not required. φ 1600- φ1900mm heads the two processes is needed.3.2pressure drum machine.(1) the main cylinder is provided with an upper die head is pressed drumexecution as long as part of.(2) supporting seat fixed lower die and upper die head center in a straight line.(3) supporting frame1is provided with a rolling wheel, a position adjusting before and after.(4) supporting frame is provided with a rolling wheel rotating disk II. In addition, there are hydraulic system, the motor, oil pump, oil tank, and a control console.3.3pressure drum machine operation steps(1) first of all to undertake a blanking process card, find a good wafer.(2) the control process card on the technological requirements, put ona set of corresponding die, and with the use of gauges to determine the selected die size and to suppress the wafer size.(3) and stamping machine is different from the original film is not pressure drum center began to suppress, but from the wafer edge, as long as the die and wafer alignment on the line.(4) the pressing process is continuously by controlling the rotation wheel is driven by the rotation of a wafer rotating, according to a certain order to suppress.(5) in after the pressing process, prepared template matching. If a deviation to make further adjustments.3.4pressure drum operation standard(1) die on the quality of the products and the smooth pressure drum forming crucial. Therefore, require that the operator must according to the processing situation of choice for mold and timely adjust shim plate.(2) the operator receives the process card, see process card, according to the process card check objects, to confirm the real instruction, one-piece, material. Number, batch number etc.. According to the choice of mold process card.(3) for EHA, EHB head shapes have adopted the 0.82*D standard selection, for DHB, PSH, MD and other special products according to technology card selection of mold, but in principle according to P*0.82/1.15or P*0.82/1.2 standard selection. [1](4) pressing carefully before inspection wafer quality, no seam wafer end is smooth, there is no gap, surface has no cutting slag and defects.(5) a weld in addition to carefully check the end of the wafer wafer defects, at the same time should be checked for weld seam is higher than that of base metal, weld ends of are welding spatter, weld end grinding smooth, there is no crack notch.(6) two or two or more superimposed when pressed, each slice of the joint surface should be clean, according to the circumstances must entrust welding class, the wafer is welded together to suppress.(7) detection of wafer thickness ( the thickest, most thin, whether and process card, measurement of wafer size and process card.(8) suppression must be removed before the inside and outside surface of all debris, to prevent pitting appeared.(9) for general stainless steel materials ( more than 5mm plate ) using Teflon plate mold and the lower mold dressing on surface polished smooth ( necessary nowadays mold to Teflon plate. ) to ensure the surface quality of the workpiece, while in the process of the pressing need to avoid debris into molds and semi-finished products. [6](10) the pressing process, when the wafer is a R shape, must use the corresponding R model measurement, the pressing process should be considered to adjust the pressure deformation degree.(11) pressing is finished, the measurement of plate thickness, measuring arc length. Check surface quality, check end and weld end is smooth ( necessary to polish out the ceremony ).(12) to check the semi-finished product with process card is on the move to the next process ( and sign the name ) by the next process to confirm acceptance before.4.spinning process4.1spinning operationThe spinning process is pressed after the drum head molding process, mainly for large head R and straight edge formation.4.2spinning machine.(1) forming wheel is connected to the corresponding mold, forming in the head inside, mold top with half formed head R and straight edge is tangent to tangent.(2) supporting wheel is also connected and molded wheel mold, forming in the head outside, and a forming wheel tangent.(3) base for fixing head, and the bottom according to head size before and after moving, the head should be installed so that the center of the base and the head of the center in a straight line.(4) the center rod is used for fixing head, and the center and the center of the base is in a straight line.In addition to the motor, a circuit board, is connected to the shaft, anda control console.4.3spinning procedure(1) to undertake pressure drum process card, according to the card to determine the corresponding head spinning.(2) according to the head of the diameter, select the corresponding upper and lower mold.(3) the clamping head, ensure that the head of the center point and the center of the base point in a straight line.(4) to adjust the molding wheel and the head of tangent, then according to the forming wheel position adjustment roller.(5) in the spinning process to observe the forming roller and the supporting roller relative position, and continue to use the template on the line alignment. Until the R reaches the requirements.4.4spinning operation standard(1) spinning wheel material for steel bearings or ductile iron, mold on the quality of the products and can spin forming closely related, therefore the operator must be processed according to choose suitable mold, at the same time, because of the shape of the mold and the surface condition of the quality of the workpiece has a great influence, therefore, before processing and machining process must on the mold for full inspection.(2) according to the process card requirements, confirm wafer, pressure drum or preload semi-finished instruction number, specifications, quantity of material, compliance, and check the quality of surface and end with no defect, abnormal timely and on the procedures of contact, and in a timely manner(3) check the semi-finished end is smooth, with or without notch, crack, surface has no cutting or welding slag, and shall inspect the weld seam is higher than that of base metal, weld ends whether spatter, weld end grinding smooth, there is no crack. [7](4) pressure drum or to the press after the finished product, must checkfor folding, cracking, crack is not conducive to the spinning processing defects.(5) for stainless steel workpiece, through to the pickling method of decontamination.(6) according to the process card selection of mold, general small arc r size requirements as a basis for selecting the internal wheel. (7) according to the different material, thickness of plate and sheet rebound, selection is slightly smaller than the internal wheel circular arc R.(8) for the special requirements of the product, according to its shape design inside the wheel, confirm the mold surface, good polishing processing.(9) spinning processing, in order to prevent scratching and improve the processing performance, suitable lubricant ( grease ) to prevent process heating head appears on the surface of hot cracks and scratches, can also prolong the service life of die.(10) the spinning process, should be considered a workpiece shaping and timely for pressure adjustment.(11) after the molding process, deal with the size, shape, thickness, surface quality inspections, confirmation.(12) molded product with the card with the transfer process to the next process ( in the process card signed their name ) by the procedures under the inspector or monitor check before.5.groove processThe 5.1groove Essentials(1) groove process is a head of the data ( including circumference, total height) to achieve JB/T4746 standard key process. [1](2) groove is in order and cylinder head connection time, make welding more thoroughly.(3) the main groove cutting process and cutting process tools, is the use of plasma cutting.(4) cutting, according to the card on the technological requirements, determine groove type ( inner groove, outside the mouth, X groove ) and determine the groove angle.(5) the groove before the head splashing agent applicator.(6) groove when the first test slope, then a protractor measuring angle, identified in the tolerance range, after adjustment, the whole slope. The 5.2groove operation standard(1) according to the process card to find real, order confirmation No., specification, material, batch number, quantity and check whether the workpiece has a drum kit, crack, delamination, wrinkle, and whether the loss of a round, found problems in a timely manner to contact, processing, the plate thickness of more than 8mm, is suggested to lose the round groove, the following 6mm, tooling plate pressure is groove.(2) stainless steel head, should be in the groove wall smearing splash front head agent, prevent groove, slag spout to head on the wall. (3) head onto the beveling machine before, first confirm the head weight, based on the weight of suitable sling, sling safety inspection.(4) head onto the groove machine, beveling rotary table adjustment screw rod, with a center adjusting position, rotating table, is aligned to the center.(5) groove, according to technology card height and height tolerance groove height ruler to draw lines, confirm the high line, the slope slope, should first slope flat groove, and then the slope groove.(6) outside the mouth or the inner groove angle should be controlled within ± 2.5 tolerance.(7) groove after, should check the head circumference, height, straight edge, angle, if not qualified to repair process, repair.(8) qualified head will remove and clean the slag grinding head internal slag, together with card transfer to the next process ( and sign their name ) by the next process inspector confirmation can be.6.polishing process6.1 polishing process steps(1) according to the card process requirements, identify the need for polishing head.(2) the head rotating table, determine the level of, the clamping head.(3) polishing from edge to center, or from the center to the edge; according to the diameter size determine the head beam, lower speed and working stage, after moving speed.(4) check the polishing condition, appropriate for rework.The 6.2polishing operation standard(1) according to the process card and materials to confirm the product instruction number, specifications, material, batch number, quantity, and check whether the workpiece has a drum kit, crack, delamination defects, and whether the loss of a round, found problems in a timely manner to contact, processing, check the appearance, to determine the need for manual processing, the polishing before hook head to mark.(2) according to the requirements of the choice of using a polishing, polishing pads, and the necessary auxiliary tool.(3) confirm the head weight, based on the weight of suitable sling, and check whether the safety hanger.(4) the head hanging onto a work table, adjust the center, at the same time to ensure that the head is in the basic level (0-5 deviations ).(5) people in the scene when polishing polishing, attention, especially the left centre, speed fast, or outward from a center left, a little pressure to increase, from the edge to the center of pressure during polishing, to a little decrease in polishing head, thin wall, as the case may be mounted shockproof wheel, at the same time attention to mechanical work has no abnormal.(6) after the completion of inspection head polishing, with or without defect, and the necessary contact.(7) the Polish well head with coated packaging, in the process card signed their names, together with the head and process the card with the circulation storage, and by the next inspection approval.封头加工工艺1.焊接工序1.1 焊接操作我们厂常用的焊接方法有：手工焊、氩弧焊、埋弧焊。
