In the process of manufacturing the loader bucket, the main blade often has deformations such as arching, falling, twisting, etc. To ensure the flatness of the main blade, we use a hydraulic press to shape, which not only prolongs the production cycle, but also increases the production cost. Moreover, the internal stress of the main blade is increased. For this reason, we analyze the structure and production process of the bucket, find the cause of the deformation of the main blade, and formulate corresponding preventive measures.
1 Analysis of the causes of deformation of the main blade of the bucket (1) Management reasons The main blade of the bucket is the external machining part after the material is cut by the material. Due to the loading, unloading, transportation and storage of the plate, the main blade appears to be arched and collapsed. And flexing deformation. For the first two types of deformation, the plate can be leveled on the hydraulic press before the welding of the bucket, but it is difficult to adjust the flexural deformation, so that it can be taken to the later group welding process.
(2) Design reasons The bottom weld of the bucket is mainly concentrated on the back side, the weld is dense and the weld form is unreasonable, so the welding workload and heat input are quite large. The bucket structure and the back weld arrangement are shown in Figure 1.
At the same time, due to the deflection of the main blade, the gap between the main blade and the bucket bottom and the bucket wall is increased and uneven. When the components are assembled according to the drawings, the intermediate parts of the docking gap are 10mm and measured respectively. At 3mm, the gap between the two ends is ≥18mm and 11mm on average (see the long dotted line in the weld layout of the back of the bucket in Figure 1). The increase of the butt gap increases the welding workload and the welding heat input. The unevenness of the gap makes the welding heat input amount uneven, and the amount of cooling shrinkage deformation after welding will be uneven, so that after the welds are cooled, the bucket will be made. The bottom plate, the bucket wall plate, and the director plate produce corresponding welding deformation.
(3) Operation reasons The bucket assembly welding process is divided into three steps: 1 bucket wall coil; 2 bucket wall and bucket side panel welding, butt main blade, bucket bottom plate, and the support plate together with the tire set welding shovel Bucket; 3 welding. These three steps are mutually independent and do not interfere with each other.
When the siding is rolled, the deformation of the main blade is caused by the uneven force at both ends or the non-parallel relationship between the pressing line and the side wall of the slab. As shown in Fig. 2, the main blade is twisted after the main blade is spliced. .
When the bottom plate of the bucket is laid, the bottom plate of the bucket is partially higher than the side panel or the main blade of the bucket due to unevenness of the bucket bottom plate or other reasons, and the plane formed by the main blade panel and the two bucket side panels is destroyed, and the bucket cannot be placed after the bucket is welded. Flat, mistakenly produced the welding deformation of the main blade, as shown in Figure 1, the local high point marked in the bucket structure diagram.
When welding the bucket, it is not executed from the viewpoint of reducing the welding deformation, and the welding sequence is performed according to the welding process, and uniform symmetrical welding is performed, especially when welding the butt welds of the main blade and the bucket wall and the bucket bottom. As a result, the welding heat input amount is excessively concentrated, and the welding deformations of the front and back sides cannot cancel each other, and the main blade plate is deformed by welding, as shown by the long dashed line in FIG.
In this way, the errors generated by the various steps and the welding deformation are concentrated together, so that the main blade is deformed after the bucket is welded.
2 Measures to prevent deformation of the main blade of the bucket (1) Strengthen the management of the main blade of the bucket and return it to the factory, and level the flatness that does not meet the requirements. For the flexural deformation, dock the panel. The edge is cut by a semi-automatic flame cutter, which ensures that the main blade is straight after processing.
(2) Improved design, the gap between the bottom plate and the main blade is reduced, from the original 10mm to 5mm, the mating clearance of 5mm from the bucket side plate is removed, and the continuous seam weld of the long round hole between the bucket wall and the wall panel is evenly distributed. The circular hole intermittent weld, the specific improvement is shown in Figure 4.
Through the above improvements, the welding heat input amount and the welding work amount can be greatly reduced, and the welding heat input amount becomes uniform and not concentrated, thereby reducing the main blade and the welding deformation.
(3) Improve the construction quality During the winding process, it is necessary to ensure that the molding line is parallel to both sides of the bucket wall, and the two ends of the bucket wall are evenly stressed to prevent distortion; when the bottom of the bucket is laid, the bottom of the bucket is flat and not higher than the sides. The plane formed by the side plate of the bucket and the main blade; the welding bucket should be welded as uniformly as possible, especially the butt weld of the main blade and the bucket bottom and the bucket wall should be divided and welded to reduce the welding heat input. And the degree of concentration of the welding heat input, so that the welding deformation of the front and back welding seams cancel each other, the specific welding sequence is shown in the numerical serial number in Figure 4.
In this three-step process, the effect of the construction operation factor causing the deformation of the main blade is minimized, thereby reducing the post-weld deformation of the main blade.
3 Conclusion Through the implementation of the above-mentioned targeted prevention measures, our company will ensure the flatness of the main blade is less than 6mm in the future production process of the loader bucket, eliminating the post-weld shaping process and shortening the production cycle. The product cost is reduced, the internal stress in the main blade is reduced, the product quality is improved, and good economic benefits are obtained.
1 Analysis of the causes of deformation of the main blade of the bucket (1) Management reasons The main blade of the bucket is the external machining part after the material is cut by the material. Due to the loading, unloading, transportation and storage of the plate, the main blade appears to be arched and collapsed. And flexing deformation. For the first two types of deformation, the plate can be leveled on the hydraulic press before the welding of the bucket, but it is difficult to adjust the flexural deformation, so that it can be taken to the later group welding process.
(2) Design reasons The bottom weld of the bucket is mainly concentrated on the back side, the weld is dense and the weld form is unreasonable, so the welding workload and heat input are quite large. The bucket structure and the back weld arrangement are shown in Figure 1.
At the same time, due to the deflection of the main blade, the gap between the main blade and the bucket bottom and the bucket wall is increased and uneven. When the components are assembled according to the drawings, the intermediate parts of the docking gap are 10mm and measured respectively. At 3mm, the gap between the two ends is ≥18mm and 11mm on average (see the long dotted line in the weld layout of the back of the bucket in Figure 1). The increase of the butt gap increases the welding workload and the welding heat input. The unevenness of the gap makes the welding heat input amount uneven, and the amount of cooling shrinkage deformation after welding will be uneven, so that after the welds are cooled, the bucket will be made. The bottom plate, the bucket wall plate, and the director plate produce corresponding welding deformation.
(3) Operation reasons The bucket assembly welding process is divided into three steps: 1 bucket wall coil; 2 bucket wall and bucket side panel welding, butt main blade, bucket bottom plate, and the support plate together with the tire set welding shovel Bucket; 3 welding. These three steps are mutually independent and do not interfere with each other.
When the siding is rolled, the deformation of the main blade is caused by the uneven force at both ends or the non-parallel relationship between the pressing line and the side wall of the slab. As shown in Fig. 2, the main blade is twisted after the main blade is spliced. .
When the bottom plate of the bucket is laid, the bottom plate of the bucket is partially higher than the side panel or the main blade of the bucket due to unevenness of the bucket bottom plate or other reasons, and the plane formed by the main blade panel and the two bucket side panels is destroyed, and the bucket cannot be placed after the bucket is welded. Flat, mistakenly produced the welding deformation of the main blade, as shown in Figure 1, the local high point marked in the bucket structure diagram.
When welding the bucket, it is not executed from the viewpoint of reducing the welding deformation, and the welding sequence is performed according to the welding process, and uniform symmetrical welding is performed, especially when welding the butt welds of the main blade and the bucket wall and the bucket bottom. As a result, the welding heat input amount is excessively concentrated, and the welding deformations of the front and back sides cannot cancel each other, and the main blade plate is deformed by welding, as shown by the long dashed line in FIG.
In this way, the errors generated by the various steps and the welding deformation are concentrated together, so that the main blade is deformed after the bucket is welded.
2 Measures to prevent deformation of the main blade of the bucket (1) Strengthen the management of the main blade of the bucket and return it to the factory, and level the flatness that does not meet the requirements. For the flexural deformation, dock the panel. The edge is cut by a semi-automatic flame cutter, which ensures that the main blade is straight after processing.
(2) Improved design, the gap between the bottom plate and the main blade is reduced, from the original 10mm to 5mm, the mating clearance of 5mm from the bucket side plate is removed, and the continuous seam weld of the long round hole between the bucket wall and the wall panel is evenly distributed. The circular hole intermittent weld, the specific improvement is shown in Figure 4.
Through the above improvements, the welding heat input amount and the welding work amount can be greatly reduced, and the welding heat input amount becomes uniform and not concentrated, thereby reducing the main blade and the welding deformation.
(3) Improve the construction quality During the winding process, it is necessary to ensure that the molding line is parallel to both sides of the bucket wall, and the two ends of the bucket wall are evenly stressed to prevent distortion; when the bottom of the bucket is laid, the bottom of the bucket is flat and not higher than the sides. The plane formed by the side plate of the bucket and the main blade; the welding bucket should be welded as uniformly as possible, especially the butt weld of the main blade and the bucket bottom and the bucket wall should be divided and welded to reduce the welding heat input. And the degree of concentration of the welding heat input, so that the welding deformation of the front and back welding seams cancel each other, the specific welding sequence is shown in the numerical serial number in Figure 4.
In this three-step process, the effect of the construction operation factor causing the deformation of the main blade is minimized, thereby reducing the post-weld deformation of the main blade.
3 Conclusion Through the implementation of the above-mentioned targeted prevention measures, our company will ensure the flatness of the main blade is less than 6mm in the future production process of the loader bucket, eliminating the post-weld shaping process and shortening the production cycle. The product cost is reduced, the internal stress in the main blade is reduced, the product quality is improved, and good economic benefits are obtained.
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Huizhou City Melors Plastic Products Co., Limited , https://www.melorsmat.com