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管件基本知(zhi)識

提起管(guan)(guan)件(jian)(jian)(jian)(jian)我(wo)(wo)們大(da)家都不陌生,在(zai)日(ri)常生活中經常能夠接觸到(dao),管(guan)(guan)件(jian)(jian)(jian)(jian)的(de)(de)(de)用途范圍(wei)非(fei)常大(da),但(dan)在(zai)我(wo)(wo)國體現的(de)(de)(de)差一些(xie),在(zai)日(ri)本(ben),無論是(shi)(shi)樣品(pin)或資(zi)(zi)料(liao)(liao)(liao)介紹,管(guan)(guan)件(jian)(jian)(jian)(jian)種類很(hen)多,各式(shi)各樣。如果要(yao)給管(guan)(guan)件(jian)(jian)(jian)(jian)下一個(ge)定義,我(wo)(wo)認為(wei)凡是(shi)(shi)管(guan)(guan)材(cai)經過深加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)生產(chan)的(de)(de)(de)產(chan)品(pin)都應該屬(shu)于(yu)管(guan)(guan)件(jian)(jian)(jian)(jian)的(de)(de)(de)范疇。日(ri)本(ben)確實(shi)如此。那么(me)管(guan)(guan)件(jian)(jian)(jian)(jian)既然是(shi)(shi)管(guan)(guan)子(zi)(zi)做(zuo)(zuo)原料(liao)(liao)(liao)通過深加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)成為(wei)一種產(chan)品(pin),所以(yi),這種產(chan)品(pin)具有(you)管(guan)(guan)子(zi)(zi)和機(ji)(ji)(ji)械(xie)零件(jian)(jian)(jian)(jian)的(de)(de)(de)雙重(zhong)特(te)性(xing)(xing),是(shi)(shi)二者的(de)(de)(de)結合。管(guan)(guan)子(zi)(zi)是(shi)(shi)管(guan)(guan)件(jian)(jian)(jian)(jian)所須的(de)(de)(de)原材(cai)料(liao)(liao)(liao),但(dan)管(guan)(guan)件(jian)(jian)(jian)(jian)的(de)(de)(de)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)方(fang)法(fa)很(hen)多,只要(yao)是(shi)(shi)機(ji)(ji)(ji)械(xie)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)的(de)(de)(de)方(fang)法(fa),它都可(ke)以(yi)應用。管(guan)(guan)件(jian)(jian)(jian)(jian)為(wei)什么(me)在(zai)國外發展(zhan)如此迅速,我(wo)(wo)認為(wei)有(you)兩個(ge)比較(jiao)突出的(de)(de)(de)優(you)(you)點(dian):是(shi)(shi)可(ke)代替部分機(ji)(ji)(ji)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)產(chan)品(pin),而且(qie)比機(ji)(ji)(ji)械(xie)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)(jian)(jian)、鑄(zhu)件(jian)(jian)(jian)(jian)、鍛造結構件(jian)(jian)(jian)(jian)重(zhong)量輕,節約材(cai)料(liao)(liao)(liao);二是(shi)(shi)比機(ji)(ji)(ji)械(xie)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)產(chan)品(pin)節省(sheng)工(gong)(gong)(gong)(gong)(gong)序、工(gong)(gong)(gong)(gong)(gong)時(shi),降低(di)工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)(jian)(jian)成本(ben)。日(ri)本(ben)材(cai)料(liao)(liao)(liao)界的(de)(de)(de)資(zi)(zi)料(liao)(liao)(liao)介紹一種卡車(che)用的(de)(de)(de)連桿機(ji)(ji)(ji)械(xie)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)方(fang)法(fa)與(yu)管(guan)(guan)件(jian)(jian)(jian)(jian)法(fa)做(zuo)(zuo)過比較(jiao),同(tong)樣的(de)(de)(de)產(chan)品(pin)重(zhong)量用的(de)(de)(de)材(cai)料(liao)(liao)(liao)重(zhong)量就不同(tong)了(le),機(ji)(ji)(ji)械(xie)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)法(fa)是(shi)(shi)10.35kg,而用管(guan)(guan)件(jian)(jian)(jian)(jian)做(zuo)(zuo)這個(ge)零件(jian)(jian)(jian)(jian)則用9.32kg,節約了(le)材(cai)料(liao)(liao)(liao);機(ji)(ji)(ji)械(xie)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)的(de)(de)(de)零件(jian)(jian)(jian)(jian)單(dan)(dan)價(jia)為(wei)240日(ri)元(yuan)(yuan),若用管(guan)(guan)件(jian)(jian)(jian)(jian)則單(dan)(dan)價(jia)為(wei)140日(ri)元(yuan)(yuan)。所以(yi)管(guan)(guan)件(jian)(jian)(jian)(jian)法(fa)在(zai)價(jia)格(ge)上很(hen)有(you)優(you)(you)勢,將近降低(di)了(le)50%。從性(xing)(xing)能上講,管(guan)(guan)件(jian)(jian)(jian)(jian)法(fa)要(yao)優(you)(you)于(yu)機(ji)(ji)(ji)械(xie)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)法(fa)。

管件(jian)種類很多,歸(gui)納有(you)以下幾(ji)種主要類型:

1.變直徑(jing)管(guan)(guan)件(jian),指管(guan)(guan)端或管(guan)(guan)上某一部分(fen)直徑(jing)減小(xiao);

2.變(bian)壁(bi)厚(hou)的管(guan)件(jian),指沿管(guan)子長度方向使壁(bi)厚(hou)發生變(bian)化;

3.改變斷面(mian)的(de)管(guan)件,根據要求,將圓(yuan)形斷面(mian)變為(wei)方形、橢圓(yuan)形、多邊形等(deng)等(deng);

4.彎曲管件,我(wo)們(men)接(jie)觸比較多的(de),就是將直管變為不同(tong)曲率(lv)半徑(jing)的(de)彎管,如彎頭、彎管等等;

5.帶凸緣(yuan)和圓緣(yuan)的管(guan)(guan)件,前(qian)者指(zhi)管(guan)(guan)子(zi)端(duan)部向內側(ce)或(huo)外側(ce)凸,后(hou)者指(zhi)在管(guan)(guan)的圓周方向形成(cheng)隆起的或(huo)凹槽的管(guan)(guan)件;

6.帶卷邊和封底(di)類的管(guan)(guan)件(jian),增(zeng)加管(guan)(guan)端(duan)總強度向管(guan)(guan)的外側(ce)或(huo)內(nei)側(ce)卷邊或(huo)將管(guan)(guan)件(jian)端(duan)部封住的管(guan)(guan)件(jian);

7.擴徑管件(jian),按照要(yao)求將管件(jian)端部或某部位擴大形(xing)成各種形(xing)狀的管件(jian);

管件的(de)加(jia)工(gong)方法(fa)(fa)也有(you)很(hen)多種。很(hen)多還屬(shu)于機(ji)械加(jia)工(gong)類的(de)范疇,用的(de)多的(de)是(shi)沖壓法(fa)(fa)、鍛壓法(fa)(fa)、滾輪加(jia)工(gong)法(fa)(fa)、滾軋(ya)法(fa)(fa)、鼓脹(zhang)法(fa)(fa)、拉伸法(fa)(fa)、彎(wan)曲法(fa)(fa)、和(he)組(zu)合加(jia)工(gong)法(fa)(fa)。管件加(jia)工(gong)是(shi)機(ji)加(jia)工(gong)和(he)金(jin)屬(shu)壓力(li)加(jia)工(gong)的(de)有(you)機(ji)結合。

現舉例說明如下:

鍛(duan)壓法:用型(xing)鍛(duan)機將管(guan)子(zi)端部或一部分予以(yi)沖(chong)伸(shen),使(shi)外徑減少(shao),常用型(xing)鍛(duan)機有(you)旋轉式、連桿式、滾輪式。

沖壓(ya)法(fa):在沖床上用帶錐度(du)的(de)芯子將管端擴到要求的(de)尺寸和形狀。

滾(gun)輪(lun)法:在管(guan)內放置芯(xin)子,外周用滾(gun)輪(lun)推壓,用于圓緣加工。

滾(gun)軋(ya)法:一般不用(yong)芯軸,適合于厚壁(bi)管內側圓緣。

彎曲(qu)成形法(fa)(fa):有三(san)種(zhong)方(fang)法(fa)(fa)較為常用,一種(zhong)方(fang)法(fa)(fa)叫(jiao)伸展法(fa)(fa),另一種(zhong)方(fang)法(fa)(fa)叫(jiao)沖壓(ya)法(fa)(fa),第(di)三(san)種(zhong)是(shi)大家(jia)較為熟悉的滾輪法(fa)(fa),有3-4個(ge)輥,兩個(ge)固定(ding)輥,一個(ge)調整輥,調整固定(ding)輥距(ju),成品管件就是(shi)彎曲(qu)的。這種(zhong)方(fang)法(fa)(fa)應用的較廣,若生產螺旋管,曲(qu)率還可大。

鼓脹(zhang)法:一種是在管(guan)內放(fang)置橡膠,上(shang)方用沖子(zi)(zi)壓(ya)縮,使管(guan)子(zi)(zi)凸出(chu)成形;另一種方法是液壓(ya)鼓脹(zhang)成形,在管(guan)子(zi)(zi)中部充入液體(ti),靠液體(ti)壓(ya)力把管(guan)子(zi)(zi)鼓成所需要的形狀,像我們(men)常(chang)用的波紋管(guan)的生(sheng)產大(da)部分用的是這種方法。

總之管(guan)件(jian)用途廣泛,種(zhong)類繁多(duo)。日本生產方(fang)(fang)法都是特許的(de),有的(de)管(guan)件(jian)生產方(fang)(fang)法和工藝都申報了,管(guan)件(jian)很(hen)(hen)多(duo),大(da)多(duo)是組合加(jia)工。我(wo)國(guo)的(de)管(guan)件(jian)加(jia)工差距很(hen)(hen)大(da),舉(ju)個(ge)例子:自行(xing)車用的(de)三通四通,在(zai)(zai)國(guo)外早在(zai)(zai)四五年就(jiu)采用鼓脹(zhang)成(cheng)形的(de)管(guan)頭,而我(wo)國(guo)的(de)廠(chang)家(jia)到現在(zai)(zai)可能(neng)還在(zai)(zai)用焊接的(de)方(fang)(fang)法。人們幾(ji)乎不(bu)認識這種(zhong)事物,很(hen)(hen)難接受(shou)新事物,即使(shi)有,廠(chang)家(jia)也不(bu)一定(ding)愿意改變這種(zhong)工藝。我(wo)國(guo)在(zai)(zai)管(guan)件(jian)這方(fang)(fang)面發(fa)展得很(hen)(hen)慢,比較落后(hou)。

 下(xia)面講一下(xia)用于管(guan)路連接(jie)(jie)的(de)管(guan)件(jian)(jian),如:彎頭(tou)、大小(xiao)頭(tou)、三通(tong)、管(guan)帽、彎管(guan)等(deng)(deng)。這些管(guan)件(jian)(jian)主要(yao)用在石油、化工(gong)、電力、造船(chuan)、建(jian)筑(zhu)行業等(deng)(deng)領(ling)域(yu)。比如:室內(nei)采(cai)暖管(guan)道有(you)的(de)要(yao)異徑連接(jie)(jie),有(you)的(de)要(yao)轉向(xiang)連接(jie)(jie),有(you)的(de)要(yao)分(fen)流連接(jie)(jie),它們分(fen)別可采(cai)用大小(xiao)頭(tou)(國(guo)外叫(jiao)異徑管(guan))、彎頭(tou)和(he)三通(tong)管(guan)件(jian)(jian)。當然這些有(you)的(de)是(shi)鑄件(jian)(jian),有(you)的(de)是(shi)由管(guan)子做(zuo)原(yuan)料通(tong)過加工(gong)的(de)方法生產。

首先我來介紹彎頭(tou)(tou)。彎頭(tou)(tou)現在國際通用(yong)的(de)(de)(de)標(biao)準(zhun)(zhun)(zhun)是(shi)美國的(de)(de)(de)國家(jia)標(biao)準(zhun)(zhun)(zhun)ansib16.9和16.28。該標(biao)準(zhun)(zhun)(zhun)的(de)(de)(de)外徑尺寸(cun)范圍(wei)是(shi)1/2″~ 80″,一般24″以內的(de)(de)(de)都(dou)(dou)是(shi)用(yong)無(wu)縫(feng)鋼(gang)管為原材(cai)料(liao),26″到(dao)80″的(de)(de)(de)都(dou)(dou)是(shi)用(yong)鋼(gang)板沖壓以后再焊(han)接(jie)。壁厚大(da)(da)可達60mm,小(xiao)(xiao)到(dao)1.24mm。鋼(gang)種用(yong)的(de)(de)(de)多(duo)的(de)(de)(de)是(shi)碳素(su)鋼(gang)(20#)、合(he)金鋼(gang)和不銹鋼(gang),共(gong)24個(ge)鋼(gang)種。鍋(guo)爐上用(yong)的(de)(de)(de)crmo鋼(gang)像15cr,用(yong)量比(bi)較大(da)(da)。三通,外徑范圍(wei)在2.5″-60″,從26″-60″為焊(han)接(jie)三通。壁厚28-60mm。大(da)(da)小(xiao)(xiao)頭(tou)(tou)規(gui)格(ge)范圍(wei),常規(gui)上先說(shuo)大(da)(da)頭(tou)(tou)規(gui)格(ge),再說(shuo)小(xiao)(xiao)頭(tou)(tou)規(gui)格(ge),大(da)(da)頭(tou)(tou)小(xiao)(xiao)0.75″,小(xiao)(xiao)頭(tou)(tou)小(xiao)(xiao)0.5″,大(da)(da)頭(tou)(tou)大(da)(da)60″,小(xiao)(xiao)頭(tou)(tou)大(da)(da)48″,20-60″為焊(han)接(jie)的(de)(de)(de),壁厚2.8-4.5mm。

下面我來(lai)講一下彎(wan)(wan)頭(tou)(tou)(tou)(tou)(tou)的(de)(de)分(fen)(fen)類方法(fa),按它的(de)(de)曲(qu)率半(ban)(ban)徑(jing)(jing)(jing)來(lai)分(fen)(fen),可分(fen)(fen)為(wei)長半(ban)(ban)徑(jing)(jing)(jing)彎(wan)(wan)頭(tou)(tou)(tou)(tou)(tou)和短(duan)半(ban)(ban)徑(jing)(jing)(jing)彎(wan)(wan)頭(tou)(tou)(tou)(tou)(tou)。長半(ban)(ban)徑(jing)(jing)(jing)彎(wan)(wan)頭(tou)(tou)(tou)(tou)(tou)指它的(de)(de)曲(qu)率半(ban)(ban)徑(jing)(jing)(jing)等(deng)于1.5倍的(de)(de)管(guan)子外徑(jing)(jing)(jing),即r=1.5d。短(duan)半(ban)(ban)徑(jing)(jing)(jing)彎(wan)(wan)頭(tou)(tou)(tou)(tou)(tou)指它的(de)(de)曲(qu)率半(ban)(ban)徑(jing)(jing)(jing)等(deng)于管(guan)子外徑(jing)(jing)(jing),即r=d。式中(zhong)的(de)(de)d為(wei)彎(wan)(wan)頭(tou)(tou)(tou)(tou)(tou)直徑(jing)(jing)(jing),r為(wei)曲(qu)率半(ban)(ban)徑(jing)(jing)(jing)。若按壓(ya)力等(deng)級來(lai)分(fen)(fen),大約有(you)(you)十(shi)七(qi)種,和美國的(de)(de)管(guan)子標準是(shi)相同的(de)(de),有(you)(you):sch5s、sch10s、sch10、sch20、sch30、sch40s、std、sch40、sch60、sch80s、xs;sch80、sch100、sch120、sch140、sch160、xxs,其(qi)中(zhong)常用(yong)的(de)(de)是(shi)std和xs兩種。按彎(wan)(wan)頭(tou)(tou)(tou)(tou)(tou)的(de)(de)角(jiao)度(du)分(fen)(fen),有(you)(you)45o彎(wan)(wan)頭(tou)(tou)(tou)(tou)(tou),有(you)(you)90o彎(wan)(wan)頭(tou)(tou)(tou)(tou)(tou)和180o彎(wan)(wan)頭(tou)(tou)(tou)(tou)(tou)。這樣一來(lai)彎(wan)(wan)頭(tou)(tou)(tou)(tou)(tou)的(de)(de)種類是(shi)很(hen)多的(de)(de),定(ding)貨時(shi)定(ding)單(dan)常采取如下表示方法(fa):如lr std 90o 8,表示長半(ban)(ban)徑(jing)(jing)(jing),壓(ya)力等(deng)級為(wei)std,90o的(de)(de)8彎(wan)(wan)頭(tou)(tou)(tou)(tou)(tou);又(you)如,sr xs 45o 4表示短(duan)半(ban)(ban)徑(jing)(jing)(jing),壓(ya)力等(deng)級為(wei)xs,45o的(de)(de)4彎(wan)(wan)頭(tou)(tou)(tou)(tou)(tou)。以上為(wei)彎(wan)(wan)頭(tou)(tou)(tou)(tou)(tou)的(de)(de)大概分(fen)(fen)類情況。

三(san)通(tong)(tong),一般有兩(liang)(liang)種。三(san)個口直(zhi)徑(jing)(jing)(jing)相(xiang)等(deng)的(de)(de)為(wei)等(deng)直(zhi)徑(jing)(jing)(jing)三(san)通(tong)(tong),兩(liang)(liang)端(duan)直(zhi)徑(jing)(jing)(jing)相(xiang)同,但匯流端(duan)直(zhi)徑(jing)(jing)(jing)與其它兩(liang)(liang)個直(zhi)徑(jing)(jing)(jing)不同稱為(wei)異徑(jing)(jing)(jing)三(san)通(tong)(tong)。表(biao)示(shi)方法如(ru)下:對于等(deng)徑(jing)(jing)(jing)三(san)通(tong)(tong),比如(ru)t3三(san)通(tong)(tong)則(ze)表(biao)示(shi)外徑(jing)(jing)(jing)是(shi)3英寸的(de)(de)等(deng)徑(jing)(jing)(jing)三(san)通(tong)(tong)。對于異徑(jing)(jing)(jing)三(san)通(tong)(tong),比如(ru)t4×4×3.5表(biao)示(shi)同徑(jing)(jing)(jing)為(wei)四(si)英寸異徑(jing)(jing)(jing)為(wei)3.5英寸的(de)(de)異徑(jing)(jing)(jing)三(san)通(tong)(tong)。壓(ya)力等(deng)級和(he)彎頭的(de)(de)壓(ya)力等(deng)級都(dou)是(shi)一樣的(de)(de),其規格(ge)范圍也是(shi)一樣的(de)(de)。

大(da)小頭,也是這(zhe)個分(fen)法(fa)。大(da)小頭的表示(shi)方(fang)法(fa)是大(da)頭直(zhi)(zhi)徑(jing)乘以(yi)小頭直(zhi)(zhi)徑(jing),例如8×6表示(shi)大(da)頭直(zhi)(zhi)徑(jing)是8英寸,小頭直(zhi)(zhi)徑(jing)是6英寸的大(da)小頭。 管(guan)件的技術要求有以(yi)下(xia)幾點:

幾何尺寸包括(kuo)外徑(jing)(jing)、內(nei)徑(jing)(jing)、壁厚(hou)。還要(yao)(yao)求控制曲率(lv)(lv)半(ban)徑(jing)(jing)。比如半(ban)徑(jing)(jing)長度(du)為(wei)(wei)1.5d,那么曲率(lv)(lv)半(ban)徑(jing)(jing)須(xu)在所要(yao)(yao)求的(de)公差范(fan)圍之內(nei)。由于(yu)這些(xie)管(guan)件(jian)大(da)(da)多數用(yong)于(yu)焊(han)接(jie),為(wei)(wei)了(le)(le)提高焊(han)接(jie)質量,端部都(dou)(dou)(dou)車成坡(po)口,留一(yi)定(ding)(ding)的(de)角度(du),帶(dai)一(yi)定(ding)(ding)的(de)邊,這一(yi)項(xiang)(xiang)要(yao)(yao)求也(ye)比較嚴,邊多厚(hou),角度(du)為(wei)(wei)多少和(he)偏差范(fan)圍都(dou)(dou)(dou)有規(gui)定(ding)(ding),幾何尺寸上比管(guan)件(jian)多了(le)(le)很多項(xiang)(xiang)。表(biao)(biao)面(mian)質量和(he)機械(xie)性能基(ji)本和(he)管(guan)子是(shi)一(yi)樣的(de)。為(wei)(wei)了(le)(le)焊(han)接(jie)方便,和(he)被連接(jie)的(de)管(guan)子的(de)鋼(gang)種(zhong)是(shi)相同(tong)的(de)。第四(si),就(jiu)(jiu)(jiu)是(shi)所有的(de)管(guan)件(jian)都(dou)(dou)(dou)要(yao)(yao)經過(guo)(guo)表(biao)(biao)面(mian)處(chu)理(li),把內(nei)外表(biao)(biao)面(mian)的(de)氧化(hua)(hua)鐵皮(pi)通過(guo)(guo)噴丸處(chu)理(li)噴掉(diao),再(zai)涂(tu)上防(fang)腐漆。這既是(shi)為(wei)(wei)了(le)(le)出口需(xu)要(yao)(yao),再(zai)者,在國內(nei)也(ye)是(shi)為(wei)(wei)了(le)(le)方便運輸防(fang)止銹蝕氧化(hua)(hua),都(dou)(dou)(dou)要(yao)(yao)做這方面(mian)的(de)工作。第五,就(jiu)(jiu)(jiu)是(shi)對包裝(zhuang)的(de)要(yao)(yao)求,對于(yu)小管(guan)件(jian),如出口,就(jiu)(jiu)(jiu)需(xu)要(yao)(yao)做木箱,大(da)(da)約1立方米(mi),規(gui)定(ding)(ding)這種(zhong)箱子中的(de)彎頭(tou)數量大(da)(da)約不(bu)能超(chao)過(guo)(guo)一(yi)噸,該(gai)標準(zhun)允許套裝(zhuang),即大(da)(da)套小,但(dan)總重量一(yi)般不(bu)可(ke)超(chao)過(guo)(guo)1噸。對于(yu)大(da)(da)件(jian)就(jiu)(jiu)(jiu)要(yao)(yao)單個包裝(zhuang),像24″的(de)就(jiu)(jiu)(jiu)須(xu)單個包裝(zhuang)。另(ling)外就(jiu)(jiu)(jiu)是(shi)包裝(zhuang)標記,標記是(shi)要(yao)(yao)注明尺寸、鋼(gang)號、批(pi)號、廠(chang)家商(shang)標。在管(guan)件(jian)上要(yao)(yao)打上鋼(gang)印,并(bing)附有裝(zhuang)箱單和(he)質保書等文件(jian)。

下(xia)(xia)(xia)面(mian)我再談(tan)一(yi)(yi)下(xia)(xia)(xia)管件生(sheng)(sheng)產的(de)(de)(de)(de)工藝(yi)流程(cheng)。以(yi)(yi)彎(wan)(wan)(wan)(wan)頭(tou)(tou)(tou)(tou)為倒,若做(zuo)長(chang)半(ban)徑(jing)(jing)彎(wan)(wan)(wan)(wan)頭(tou)(tou)(tou)(tou),如用天管公司的(de)(de)(de)(de)管,要(yao)(yao)先選定(ding)(ding)規(gui)格,提出管料(liao)(liao)。擴(kuo)徑(jing)(jing)率,通過(guo)理論計算(suan),一(yi)(yi)般(ban)(ban)擴(kuo)徑(jing)(jing)率在33%-35%之(zhi)間,倒推(tui)(tui)(tui)(tui)回去。短半(ban)徑(jing)(jing)219mm的(de)(de)(de)(de)一(yi)(yi)般(ban)(ban)的(de)(de)(de)(de)擴(kuo)徑(jing)(jing)率為50%。選好(hao)原料(liao)(liao)后(hou),按(an)彎(wan)(wan)(wan)(wan)頭(tou)(tou)(tou)(tou)規(gui)格下(xia)(xia)(xia)料(liao)(liao),再考慮曲率半(ban)徑(jing)(jing), 比如,90°的(de)(de)(de)(de)彎(wan)(wan)(wan)(wan)頭(tou)(tou)(tou)(tou),通過(guo)其曲率可以(yi)(yi)算(suan)出下(xia)(xia)(xia)多長(chang)料(liao)(liao)可加(jia)工出90°的(de)(de)(de)(de)彎(wan)(wan)(wan)(wan)頭(tou)(tou)(tou)(tou)。通過(guo)理論計算(suan)可算(suan)出,然后(hou)以(yi)(yi)該長(chang)度為定(ding)(ding)尺(chi)進(jin)行(xing)(xing)切斷(duan)。把(ba)(ba)料(liao)(liao)進(jin)行(xing)(xing)熱(re)推(tui)(tui)(tui)(tui)制(zhi)(zhi)。推(tui)(tui)(tui)(tui)制(zhi)(zhi)機(ji)(ji)大家可能都(dou)看過(guo),實(shi)際很(hen)簡單。它是(shi)(shi)(shi)(shi)(shi)一(yi)(yi)個(ge)(ge)(ge)(ge)牛角狀芯(xin)頭(tou)(tou)(tou)(tou)或(huo)芯(xin)棒(bang)(bang),芯(xin)棒(bang)(bang)由(you)細(xi)變粗,推(tui)(tui)(tui)(tui)制(zhi)(zhi)過(guo)程(cheng)是(shi)(shi)(shi)(shi)(shi)一(yi)(yi)個(ge)(ge)(ge)(ge)擴(kuo)徑(jing)(jing)帶(dai)彎(wan)(wan)(wan)(wan)曲的(de)(de)(de)(de)過(guo)程(cheng)。后(hou)邊有支撐,把(ba)(ba)下(xia)(xia)(xia)料(liao)(liao)管段穿入芯(xin)棒(bang)(bang),后(hou)邊有一(yi)(yi)牌坊架將(jiang)芯(xin)棒(bang)(bang)固定(ding)(ding)。中(zhong)間有一(yi)(yi)小(xiao)車(che),小(xiao)車(che)有的(de)(de)(de)(de)通過(guo)液壓傳(chuan)動,有的(de)(de)(de)(de)通過(guo)機(ji)(ji)械傳(chuan)動即絲杠傳(chuan)動,然后(hou)往前推(tui)(tui)(tui)(tui)小(xiao)車(che)。小(xiao)車(che)推(tui)(tui)(tui)(tui)著管子(zi)順著芯(xin)棒(bang)(bang)往前走,芯(xin)棒(bang)(bang)外(wai)有一(yi)(yi)個(ge)(ge)(ge)(ge)感應(ying)圈(quan),把(ba)(ba)管子(zi)加(jia)熱(re),加(jia)熱(re)好(hao),然后(hou)小(xiao)車(che)把(ba)(ba)管子(zi)推(tui)(tui)(tui)(tui)下(xia)(xia)(xia),就加(jia)工好(hao)一(yi)(yi)個(ge)(ge)(ge)(ge)。推(tui)(tui)(tui)(tui)好(hao)后(hou),彎(wan)(wan)(wan)(wan)頭(tou)(tou)(tou)(tou)要(yao)(yao)就此熱(re)狀態下(xia)(xia)(xia)進(jin)行(xing)(xing)整(zheng)(zheng)形(xing)。因為有的(de)(de)(de)(de)彎(wan)(wan)(wan)(wan)頭(tou)(tou)(tou)(tou)處理不(bu)當后(hou),就會(hui)扭曲,這是(shi)(shi)(shi)(shi)(shi)不(bu)允許(xu)的(de)(de)(de)(de)。另外(wai),推(tui)(tui)(tui)(tui)頭(tou)(tou)(tou)(tou)后(hou)一(yi)(yi)般(ban)(ban)都(dou)是(shi)(shi)(shi)(shi)(shi)前端外(wai)徑(jing)(jing)大,要(yao)(yao)通過(guo)整(zheng)(zheng)形(xing)模(mo)進(jin)行(xing)(xing)整(zheng)(zheng)形(xing)。整(zheng)(zheng)形(xing)模(mo)實(shi)際上(shang)是(shi)(shi)(shi)(shi)(shi)一(yi)(yi)個(ge)(ge)(ge)(ge)壓力機(ji)(ji),要(yao)(yao)有一(yi)(yi)套模(mo)具,兩個(ge)(ge)(ge)(ge)半(ban)圓弧,上(shang)下(xia)(xia)(xia)各一(yi)(yi)個(ge)(ge)(ge)(ge)。整(zheng)(zheng)形(xing)后(hou)的(de)(de)(de)(de)外(wai)徑(jing)(jing)就達到(dao)了(le)(le)成(cheng)品的(de)(de)(de)(de)尺(chi)寸要(yao)(yao)求(qiu)了(le)(le)。壁(bi)厚就以(yi)(yi)來料(liao)(liao)的(de)(de)(de)(de)壁(bi)厚進(jin)行(xing)(xing)控制(zhi)(zhi)。彎(wan)(wan)(wan)(wan)頭(tou)(tou)(tou)(tou)和管子(zi)的(de)(de)(de)(de)壁(bi)厚公差都(dou)是(shi)(shi)(shi)(shi)(shi)相同(tong)(tong)的(de)(de)(de)(de),均為±12.5%。在推(tui)(tui)(tui)(tui)制(zhi)(zhi)過(guo)程(cheng)中(zhong),正常情況(kuang)下(xia)(xia)(xia)壁(bi)厚不(bu)應(ying)當發生(sheng)(sheng)變化,但如果因為工具原因,有的(de)(de)(de)(de)地方會(hui)發生(sheng)(sheng)減(jian)壁(bi)現象(xiang),所(suo)以(yi)(yi)一(yi)(yi)般(ban)(ban)提料(liao)(liao)時(shi),壁(bi)厚要(yao)(yao)加(jia)一(yi)(yi)些余量,如彎(wan)(wan)(wan)(wan)頭(tou)(tou)(tou)(tou)是(shi)(shi)(shi)(shi)(shi)8.18mm的(de)(de)(de)(de)壁(bi)厚,一(yi)(yi)般(ban)(ban)都(dou)提8.5mm左(zuo)右的(de)(de)(de)(de)管子(zi),防止在推(tui)(tui)(tui)(tui)制(zhi)(zhi)時(shi)由(you)于局(ju)部減(jian)厚而超差。整(zheng)(zheng)好(hao)形(xing)后(hou),彎(wan)(wan)(wan)(wan)頭(tou)(tou)(tou)(tou)的(de)(de)(de)(de)外(wai)徑(jing)(jing)、壁(bi)厚尺(chi)寸都(dou)達到(dao)了(le)(le)要(yao)(yao)求(qiu)。下(xia)(xia)(xia)面(mian)就進(jin)行(xing)(xing)精整(zheng)(zheng)工序,經過(guo)噴丸處理,把(ba)(ba)彎(wan)(wan)(wan)(wan)頭(tou)(tou)(tou)(tou)內外(wai)表面(mian)的(de)(de)(de)(de)氧化鐵皮(pi)去除(chu),把(ba)(ba)兩端進(jin)行(xing)(xing)坡口處理以(yi)(yi)便(bian)于焊(han)接(jie)。再經過(guo)檢查(cha)、打鋼字、噴涂漆、包裝等(deng)工序后(hou),就可以(yi)(yi)出廠了(le)(le)。以(yi)(yi)上(shang)是(shi)(shi)(shi)(shi)(shi)24″以(yi)(yi)下(xia)(xia)(xia)以(yi)(yi)無縫(feng)鋼管作為原料(liao)(liao)的(de)(de)(de)(de)彎(wan)(wan)(wan)(wan)頭(tou)(tou)(tou)(tou)生(sheng)(sheng)產方法,超過(guo)24″以(yi)(yi)后(hou)即600mm以(yi)(yi)上(shang)的(de)(de)(de)(de),大彎(wan)(wan)(wan)(wan)頭(tou)(tou)(tou)(tou)在2.032米(mi)~2.80米(mi)之(zhi)間,是(shi)(shi)(shi)(shi)(shi)用鋼板做(zuo)的(de)(de)(de)(de)。把(ba)(ba)鋼板按(an)要(yao)(yao)求(qiu)裁成(cheng)料(liao)(liao)后(hou),像uoe成(cheng)型,也是(shi)(shi)(shi)(shi)(shi)通過(guo)沖(chong)(chong)模(mo)沖(chong)(chong)壓沖(chong)(chong)成(cheng)圓形(xing)。有兩半(ban)然后(hou)再拼合、焊(han)接(jie)。由(you)于焊(han)縫(feng)的(de)(de)(de)(de)存在,所(suo)以(yi)(yi)要(yao)(yao)進(jin)行(xing)(xing)無損探傷(shang)。由(you)于有焊(han)接(jie)應(ying)力的(de)(de)(de)(de)存在,所(suo)以(yi)(yi)還(huan)要(yao)(yao)進(jin)行(xing)(xing)熱(re)處理。焊(han)接(jie)彎(wan)(wan)(wan)(wan)頭(tou)(tou)(tou)(tou)多了(le)(le)兩道(dao)工序:一(yi)(yi)是(shi)(shi)(shi)(shi)(shi)探傷(shang),一(yi)(yi)是(shi)(shi)(shi)(shi)(shi)熱(re)處理。其他程(cheng)序相同(tong)(tong)。

三通的(de)生(sheng)產(chan)工(gong)(gong)藝(yi)也(ye)基本是(shi)如此。要根據三通的(de)不同規(gui)格進(jin)行下料。下料后先要噴砂,要在(zai)成(cheng)形(xing)前將(jiang)表面的(de)氧化(hua)鐵皮去除(chu)(chu)。成(cheng)形(xing)則(ze)采用液(ye)(ye)壓(ya)鼓脹法成(cheng)形(xing)。有模具,模具底部平直(zhi),上(shang)邊有凸緣孔。將(jiang)管(guan)子放(fang)入(ru)后,管(guan)子用液(ye)(ye)壓(ya)缸固定,兩邊充(chong)入(ru)液(ye)(ye)體(ti)向內凸脹,把(ba)管(guan)擠成(cheng)凸字形(xing),再(zai)把(ba)凸起處(chu)從適當位置切除(chu)(chu),也(ye)打成(cheng)坡口(kou)。它要經過(guo)兩次噴丸處(chu)理。由于加工(gong)(gong)過(guo)程(cheng)中(zhong),有加工(gong)(gong)硬化(hua),所以也(ye)需(xu)要熱處(chu)理。管(guan)件的(de)生(sheng)產(chan)工(gong)(gong)藝(yi)流程(cheng)就是(shi)這些情況。

需要(yao)(yao)(yao)再說(shuo)明的(de)是(shi)切(qie)斷(duan),要(yao)(yao)(yao)求一定采(cai)用(yong)切(qie)管(guan)機(ji),再有(you)鋸床(chuang),大(da)(da)一些(xie)的(de)規格就采(cai)用(yong)火焰切(qie)割。無論采(cai)用(yong)什么(me)方(fang)法(fa),一定要(yao)(yao)(yao)保(bao)證管(guan)端平直、無毛刺、定尺準確。否則(ze),在推(tui)(tui)制(zhi)(zhi)過(guo)程中(zhong),管(guan)端容易破裂。推(tui)(tui)制(zhi)(zhi)這(zhe)方(fang)面的(de)技術(shu)問題(ti),在于工具設(she)(she)計(ji)(ji)。若設(she)(she)計(ji)(ji)的(de)好(hao),推(tui)(tui)出來的(de)型比(bi)(bi)較(jiao)(jiao)正,基(ji)本符合要(yao)(yao)(yao)求。有(you)的(de)廢品較(jiao)(jiao)多,主要(yao)(yao)(yao)是(shi)由于工具問題(ti)。設(she)(she)計(ji)(ji)主要(yao)(yao)(yao)是(shi)憑(ping)經(jing)驗(yan)(yan)。還(huan)需要(yao)(yao)(yao)有(you)經(jing)驗(yan)(yan)的(de)工人不(bu)斷(duan)修磨,才(cai)(cai)能投入正常(chang)使用(yong)。工具很重要(yao)(yao)(yao)。另(ling)外,推(tui)(tui)制(zhi)(zhi)現在都采(cai)用(yong)液壓(ya)的(de)推(tui)(tui)制(zhi)(zhi)方(fang)法(fa)。液壓(ya)推(tui)(tui)制(zhi)(zhi)速(su)度可調。大(da)(da)彎(wan)頭與小彎(wan)頭的(de)推(tui)(tui)制(zhi)(zhi)速(su)度是(shi)不(bu)同的(de),加(jia)(jia)熱(re)(re)(re)(re)速(su)度也不(bu)相同。另(ling)外用(yong)液壓(ya)推(tui)(tui)制(zhi)(zhi)的(de)變形也比(bi)(bi)較(jiao)(jiao)平穩。現在機(ji)械推(tui)(tui)制(zhi)(zhi)的(de)方(fang)法(fa)已經(jing)不(bu)很多了(le),加(jia)(jia)熱(re)(re)(re)(re)也比(bi)(bi)較(jiao)(jiao)重要(yao)(yao)(yao)。老式(shi)的(de)加(jia)(jia)熱(re)(re)(re)(re)采(cai)用(yong)煤氣爐,把管(guan)子(zi)加(jia)(jia)熱(re)(re)(re)(re),現在都改用(yong)中(zhong)頻加(jia)(jia)熱(re)(re)(re)(re)。約在70年代以(yi)后我國的(de)這(zhe)種(zhong)加(jia)(jia)熱(re)(re)(re)(re)方(fang)式(shi)才(cai)(cai)過(guo)關。這(zhe)種(zhong)方(fang)法(fa)溫度比(bi)(bi)較(jiao)(jiao)好(hao)控(kong)制(zhi)(zhi),加(jia)(jia)熱(re)(re)(re)(re)也比(bi)(bi)較(jiao)(jiao)均勻(yun)。通過(guo)調節線圈的(de)個數來控(kong)制(zhi)(zhi)加(jia)(jia)熱(re)(re)(re)(re)溫度。若是(shi)燒咀,就不(bu)太好(hao)控(kong)制(zhi)(zhi)。另(ling)外推(tui)(tui)制(zhi)(zhi)前要(yao)(yao)(yao)預熱(re)(re)(re)(re)。芯棒預熱(re)(re)(re)(re)后再固定管(guan)子(zi)。中(zhong)頻加(jia)(jia)熱(re)(re)(re)(re)技術(shu)的(de)采(cai)用(yong)對彎(wan)頭生(sheng)產(chan)是(shi)很大(da)(da)的(de)進步(bu),產(chan)量(liang)、質(zhi)量(liang)都有(you)很大(da)(da)提高。

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