CN116810319B - Processing technology and application of high-pressure clamp - Google Patents
Processing technology and application of high-pressure clamp Download PDFInfo
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- CN116810319B CN116810319B CN202311103974.8A CN202311103974A CN116810319B CN 116810319 B CN116810319 B CN 116810319B CN 202311103974 A CN202311103974 A CN 202311103974A CN 116810319 B CN116810319 B CN 116810319B
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- 238000012545 processing Methods 0.000 title claims abstract description 28
- 238000005516 engineering process Methods 0.000 title claims abstract description 23
- 238000005242 forging Methods 0.000 claims abstract description 95
- 239000000463 material Substances 0.000 claims abstract description 29
- 238000004519 manufacturing process Methods 0.000 claims abstract description 17
- 239000003973 paint Substances 0.000 claims abstract description 17
- 238000009966 trimming Methods 0.000 claims abstract description 13
- 230000007797 corrosion Effects 0.000 claims abstract description 11
- 238000005260 corrosion Methods 0.000 claims abstract description 11
- 238000005507 spraying Methods 0.000 claims abstract description 8
- 238000007689 inspection Methods 0.000 claims abstract description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 6
- 239000000126 substance Substances 0.000 claims abstract description 5
- 239000003595 mist Substances 0.000 claims abstract description 4
- 239000013535 sea water Substances 0.000 claims abstract description 4
- 238000010438 heat treatment Methods 0.000 claims description 33
- 229910000831 Steel Inorganic materials 0.000 claims description 14
- 239000010959 steel Substances 0.000 claims description 14
- 238000005422 blasting Methods 0.000 claims description 13
- 238000000034 method Methods 0.000 claims description 13
- 239000007769 metal material Substances 0.000 claims description 11
- 230000008569 process Effects 0.000 claims description 9
- 238000005498 polishing Methods 0.000 claims description 5
- 238000001514 detection method Methods 0.000 claims description 4
- 238000003801 milling Methods 0.000 abstract description 4
- 238000003860 storage Methods 0.000 abstract description 4
- 238000005553 drilling Methods 0.000 abstract description 3
- 238000007667 floating Methods 0.000 abstract description 3
- 238000009434 installation Methods 0.000 abstract description 3
- 239000003245 coal Substances 0.000 abstract description 2
- 238000005504 petroleum refining Methods 0.000 abstract description 2
- 239000011248 coating agent Substances 0.000 description 10
- 238000000576 coating method Methods 0.000 description 10
- 238000003754 machining Methods 0.000 description 5
- 229910001069 Ti alloy Inorganic materials 0.000 description 4
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 4
- 239000004810 polytetrafluoroethylene Substances 0.000 description 4
- 239000004809 Teflon Substances 0.000 description 3
- 229920006362 Teflon® Polymers 0.000 description 3
- 238000001354 calcination Methods 0.000 description 3
- 238000004939 coking Methods 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
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- 241000287828 Gallus gallus Species 0.000 description 2
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- 238000005336 cracking Methods 0.000 description 2
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- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 2
- 230000007803 itching Effects 0.000 description 2
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- 229920001221 xylan Polymers 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Forging (AREA)
Abstract
The application discloses a processing technology of a high-pressure clamp, which comprises the following steps: (1) blanking; (2) forging; (3) hot trimming; (4) forging inspection; (5) post-treatment; (6) inspecting the finished product; (7) paint spraying; and (8) warehousing. The application is mainly applied to floating production oil storage and offloading ships (FPSOs), offshore drilling platforms and production platforms, is high-pressure resistant, medium corrosion resistant and environment resistant (seawater and water mist environments), is used for connecting high-pressure clamp flanges, has the important characteristics of high strength and corrosion resistance compared with common clamps for petroleum refining, coal chemical industry and industrial pipelines, is integrally manufactured and formed by forging, and has the advantages of high material utilization rate, high production efficiency, low emission, uniform material performance and reduced installation difficulty compared with the traditional milling process.
Description
Technical Field
The application relates to a processing technology of a high-pressure clamp and application thereof, in particular to the field of basic non-cutting processing or treatment of sectional materials.
Background
The clamp is a connecting device for connecting pipe fittings, valves and pipeline fittings, and plays a role of clamping connection at joints. In order to improve the strength of the clamp, the clamp can be applied to large oil storage and unloading ships, offshore operation platforms and the like, and not only the metal material components of the clamp are required to be optimized, but also the machining procedure of the clamp is required to be optimized. The existing clamp processing technology is that circular forgings are sawed and then shaped and milled, the hardness of metal materials and the mechanical property are improved, so that the difficulty of forgings in sawing and milling processes is increased, the utilization rate of forging materials is low, and the production efficiency is poor. The application creatively adopts the non-cutting processing forging high-pressure clamp, so that the clamp is integrally formed, the production efficiency is improved, and the material utilization rate of the forging is increased.
Chinese patent No. 201510784706.6 discloses a method for forming die forgings of titanium alloy clips, in which diamond-shaped titanium alloy blanks are punched in a free forging machine and then are placed in a forging die, the die forgings are forged into the die forgings of the clips by the die forging machine, and then the final products are obtained through trimming and punching processes, so that the forming load required by die forging is reduced, the service life of the die is prolonged, meanwhile, the consumption of valuable raw materials is reduced, the quality of the titanium alloy forgings is ensured, but the cost of the titanium alloy clips is high, and the die forgings are not suitable for mass production and use. Chinese patent No. CN202210786447.0 discloses a method for forming a high-temperature and high-pressure quick-release clamp body, which comprises rough machining a semi-clamp blank into a semi-ring shape by wire cutting, and then machining the semi-clamp to a rated thickness by grinding; and the milling tool is used for finishing the machining of the connecting parts at two ends and the profile, and the turning is used for precisely machining the V-shaped groove, so that the precise production of the clamp size is realized, and the rejection rate is reduced. But the utilization rate of the forging raw materials is not high, and the production efficiency is lower.
Disclosure of Invention
In order to improve the mechanical strength and corrosion resistance of the clamp, a first aspect of the application provides a processing technology of a high-pressure clamp, comprising the following steps: (1) blanking; (2) forging; (3) hot trimming; (4) forging inspection; (5) post-treatment; (6) inspecting the finished product; (7) paint spraying; and (8) warehousing.
As a preferable implementation mode, the blanking is to control the weight of the metal material to be 23-24kg, the slope of the blanking saw face is less than or equal to 2 degrees, the metal material is placed neatly, and steel nails and flanging on the side edges of the head and the tail of the material are removed.
As a preferred embodiment, the metal material is a steel material, and the chemical components in the steel material include, in weight percent: 0.38-0.43% of C, 0.75-1% of Mn, 0.15-0.35% of Si, less than or equal to 0.035% of P, less than or equal to 0.04% of S, 0.8-1.1% of Cr, 0.15-0.25% of Mo and the balance of Fe.
The applicant finds that the clamp formed by blanking and forging the steel material with the weight fraction of Cr of 0.8-1.1%, the weight fraction of Mo of 0.15-0.25% and the weight fraction of C of 0.38-0.43% can meet the requirements of high strength and high mechanical property in the experimental process. The possible reasons for the guess are: the existence of the die in the forging process enables the stress on the outer edge and the inner structure of the product to be different, the weight fraction of Cr is 0.8-1.1%, the mass fraction of Mo is 0.15-0.25%, the mass fraction of C is 0.38-0.43% of steel, the grain size of the area of the forging is consistent, the dynamic change of grains at different positions can be reduced, the integral recrystallization proportion of the forging is small, the formed microstructure is uniform, and abnormal growth of the grains is avoided. The formed forge piece is uniform in material quality in each area, so that the forge piece is good in mechanical property and free of stress defects when subjected to external force, and can be applied to high-pressure and high-strength environments.
As a preferred embodiment, the forging includes heating, flattening, pre-forging and finish forging, and the heating is heating using an intermediate frequency furnace, and the heating is followed by a hot blank.
As a preferred embodiment, the parameters of the heating are: the heating voltage is 1000-1100V, the heating beat is 20-30s, the heating temperature is 1100-1200 ℃, and the final forging temperature is more than or equal to 950 ℃.
The applicant adopts 1000-1100V heating voltage in the experimental process, controls the heating temperature to 1100-1200 ℃ so as to facilitate subsequent calcination processing, reduce blank coking and overburning, and generate defective products. The reason for the guess may be: the blank formed at the heating temperature of 1100-1200 ℃ has certain hardness, so that the metal fiber structure can maintain certain continuity, but no flow state is formed, the metal streamline is complete, and the structure is compact. And the green body has certain toughness, can be pressed into the thickness of 90mm, and is favorable for subsequent calcination processing. However, under the heating voltage of 1000-1100V, although rapid heating can be realized, sticking materials can occur during discharging of a furnace mouth, so that the heating temperature is higher, the temperature needs to be reduced, and the problems of coking and overburning of metal materials can occur otherwise.
As a preferred embodiment, the specific steps of the flattening are as follows: after the hot blank is placed in the middle of the die and is stable, an air hammer is used for flattening the blank to 89-91mm.
As a preferred embodiment, the specific steps of pre-forging and final-forging are as follows: and (3) pre-forging the flattened hot blank, placing the clamped pre-forged hot blank in the middle of a forging die cavity, and then starting forging, wherein forging parameters are 1-2s, so as to obtain the hot forging.
As a preferred embodiment, after the hot forging is removed, the mold needs to be cooled in time to lubricate the mold cavity. Before the hot blank is put into, the water in the forging die cavity is blown clean, so that the quality of the forging is prevented from being influenced.
As a preferred embodiment, the mold includes an upper mold frame, an upper mold, a lower mold, and a lower mold frame. When the mold is severely worn and chicken feet and big burrs appear, the mold should be replaced in time.
As a preferred embodiment, the misalignment distance between the hot blank and the die is less than or equal to 0.5mm.
As a preferred embodiment, the hot trimming is: and (3) flatly placing the hot forging into a trimming die for trimming, and after the trimming is finished once, removing the residual flash, placing the next hot forging, wherein the residual flash is less than or equal to 0.5mm.
As a preferable implementation mode, the forging inspection is to check whether the forging has defects such as folding, cracking, overburning, material shortage and the like, and the itching skin pit is less than or equal to 0.5mm.
The applicant finds that in the experimental process, the error die distance of the forging piece is controlled to be less than or equal to 0.5mm, the residual flash is controlled to be less than or equal to 0.5mm, the yield strength of the forging piece can be improved, and the tensile strength and the shock resistance are improved. The possible reasons for the guess are: through the wrong mould distance of control forging, can make the forging evenly spread in the mould, the folding problem of material body can not appear to the material body receives stress evenly in the mould, prevents that the material body from appearing the material loose, appears the microcrack. The forging with small die staggering distance and small residual flash is uniform in the deformation force of the die, proper in deformation speed, capable of further avoiding the generation of forging folding and cracks, smooth in the formed forging metal tissue lines and good in plasticity.
In addition, the die just manufactured by the die has high strength, the die is uniformly applied with force and pressure by the upper die carrier, casting dendrites in the blank can be crushed and compacted, and loose cavities can be crushed and compacted, so that the mechanical property of the forge piece is further improved, and the forge piece has high yield strength, good tensile strength and good shock resistance.
As a preferred embodiment, the post-treatment comprises: shot blasting, polishing, flaw detection and single treatment of 50-70 shot blasting machines, wherein the shot blasting time is 13-16min. After shot blasting, the surface of the forging piece has no oxide scale residue and no rust.
As a preferred embodiment, polishing is performed as required, and burrs are removed from the forging; and the flaw detection adopts a magnetic powder flaw detector.
As a preferred embodiment, the paint is 100% paint on the surface, and the thickness of the paint is 10-35 μm.
As a preferred embodiment, the paint is a PTFE coating.
The applicant finds that the friction force on the surface of the forged clamp forging is large after forging in the experimental process, and a small amount of oxide pits are formed on the surface of the forged clamp forging after high-temperature forging, so that the forged clamp forging is easy to oxidize during direct use, and the applicant finds that the oxidation of the clamp can be reduced and the corrosion resistance can be improved by spraying a Teflon coating, and the friction force on the surface of the clamp can be reduced under the thickness of the coating of 25 mu m, so that the installation and the use of the clamp and the flange are facilitated. The possible reason is that a small amount of oxide pits remain on the surface of the forged clamp, and the pits can be buried by spraying the paint of 25 mu m to form a flat and smooth surface, so that the surface friction is reduced. However, when the thickness exceeds the preferable thickness, the adhesion between the coating and the clamp body is lowered, the cohesion of the coating is high, and the coating is easily peeled off, which is rather unfavorable for the improvement of corrosion performance.
The second aspect of the application provides an application of the processing technology of the high-pressure clamp, which is applied to the production of the clamp with high pressure resistance, medium corrosion resistance, seawater resistance and water mist resistance.
As a preferred embodiment, the process is applied to the production of clips for floating production oil storage and offloading vessels, offshore drilling platforms, offshore production platforms.
Compared with the prior art, the application has the following beneficial effects:
(1) According to the processing technology of the high-pressure clamp, the clamp formed by blanking and forging the steel material with the weight fraction of Cr of 0.8-1.1%, the weight fraction of Mo of 0.15-0.25% and the weight fraction of C of 0.38-0.43% can meet the requirements of high strength and high mechanical property, and has the advantages of high extensibility, good area shrinkage, impact resistance and high hardness.
(2) The processing technology of the high-pressure clamp adopts the heating voltage of 1000-1100V, controls the heating temperature to 1100-1200 ℃ so as to facilitate subsequent calcination processing, reduces the coking and overburning of blanks and produces defective products.
(3) According to the processing technology of the high-pressure clamp, disclosed by the application, the die staggering distance of a forging piece is controlled to be less than or equal to 0.5mm, and the residual flash is controlled to be less than or equal to 0.5mm, so that the yield strength of the forging piece can be improved, and the tensile strength and the shock resistance can be improved.
(4) According to the processing technology of the high-pressure clamp, the PTFE coating is adopted for spraying, the spraying thickness is 25 mu m, the friction coefficient of the clamp and the inclined plane of the flange is reduced, the clamp and the flange are convenient to install, the clamp has an excellent corrosion resistance effect, and the processing technology can be applied to marine environments.
(5) The clamp produced by the processing technology is mainly applied to floating production oil storage and offloading vessels (FPSOs), offshore drilling platforms and production platforms, is high-pressure resistant, medium corrosion resistant and environment resistant (seawater and water mist environments), is used for connecting a high-pressure clamp flange, and has the important characteristics of high strength and corrosion resistance compared with common clamps for petroleum refining, coal chemical industry and industrial pipelines.
(6) Compared with the traditional milling process, the processing technology of the high-pressure clamp has the advantages of high material utilization rate, high production efficiency, low emission, uniform material performance and reduced installation difficulty due to the adoption of the coating.
Drawings
FIG. 1 is a perspective view of a high pressure clamp made in accordance with the present application, shown in FIG. 1;
FIG. 2 is a perspective view of a high pressure clamp made in accordance with the present application;
fig. 3 is a perspective view of a die for a high pressure clip made in accordance with the present application.
In fig. 3: 1. a die carrier is arranged; 2. an upper die; 3. a lower die; 4. and (5) lower die carrier.
Detailed Description
Example 1
A processing technology of a high-pressure clamp comprises the following steps: (1) blanking; (2) forging; (3) hot trimming; (4) forging inspection; (5) post-treatment; (6) inspecting the finished product; (7) paint spraying; and (8) warehousing.
The blanking is to control the weight of the metal material to be 23.4kg, the slope of the blanking saw face to be 2 degrees, the feeding is orderly arranged, and steel nails of the head and the tail of the material and flanging of the side edges are removed.
The metal material is a steel material, and the steel material comprises the following chemical components in percentage by weight: 0.38-0.43% of C, 0.75-1% of Mn, 0.15-0.35% of Si, less than or equal to 0.035% of P, less than or equal to 0.04% of S, 0.8-1.1% of Cr, 0.15-0.25% of Mo and the balance of Fe. The steel material is AISI4140 100K.
The forging comprises heating, flattening, pre-forging and final-forging, wherein the heating is performed by using an intermediate frequency furnace, and a hot blank is obtained after the heating.
The parameters of the heating are as follows: the heating voltage is 1050V, the heating beat is 25s, the heating temperature is 1150 ℃, and the final forging temperature is 950 ℃.
The flattening method comprises the following specific steps: after the hot blank was placed in the middle of the die to a stable position, the blank was flattened to 90mm using an air hammer.
The specific steps of pre-forging and final-forging are as follows: and (3) pre-forging the flattened hot blank, placing the clamped pre-forged hot blank in the middle of a forging die cavity, and then starting forging, wherein forging parameters are 1.5s, so as to obtain the hot forging. After the hot forging is taken out, the die is required to be cooled in time, and the die cavity is lubricated. Before the hot blank is put into, the water in the forging die cavity is blown clean, so that the quality of the forging is prevented from being influenced. The die comprises an upper die frame 1, an upper die 2, a lower die 3 and a lower die frame 4. When the mold is severely worn and chicken feet and big burrs appear, the mold should be replaced in time. The die-staggering distance between the hot blank and the die is less than or equal to 0.5mm.
The hot trimming is as follows: and (3) flatly placing the hot forging into a trimming die for trimming, and after the trimming is finished once, removing the residual flash, placing the next hot forging, wherein the residual flash is less than or equal to 0.5mm.
The forging inspection is to check whether the forging has defects such as folding, cracking, overburning, material shortage and the like, and the itching skin pit is less than or equal to 0.5mm.
The post-processing includes: shot blasting, polishing and flaw detection, wherein a shot blasting machine is adopted for shot blasting, 60 pieces are processed by the shot blasting machine once, and the shot blasting time is 15 minutes. After shot blasting, the surface of the forging piece has no oxide scale residue and no rust. Polishing is carried out according to the requirement, and burrs are removed from the forging.
The paint is 100% paint on the surface, and the thickness of the paint is 25 mu m; the paint was a PTFE coating, available from Hua Fu Teflon under the model number Xylan 1424.
The product is shown in figure 1.
Example 2
The processing technology of the high-pressure clamp and the application thereof are characterized in that the processing technology comprises the following specific steps as in the embodiment 1, wherein the specific steps are as follows: 0.045-0.15% of C, 0.5-1% of Mn, 0.45-1% of Si, less than or equal to 0.04% of P, less than or equal to 0.03% of S, 11.5-13.5% of Cr, 0.15-0.25% of Mo and the balance of Fe. The steel material is AISI4100.
Example 3
The specific steps of the processing technology of the high-pressure clamp and the application thereof are the same as those of the embodiment 1, and the difference is that the heating parameters are as follows: the heating voltage is 1100V, the heating beat is 30s, the heating temperature is 1250 ℃, and the final forging temperature is 950 ℃.
Example 4
A processing technology of a high-pressure clamp and application thereof are the same as in the embodiment 1, except that the die-staggering distance between the hot blank and the die is 0.6mm.
Example 5
A processing technology of a high-pressure clamp and application thereof are characterized in that the specific steps are the same as those of the embodiment 1, and the difference is that the spray paint is a corrosion-resistant Teflon PTFE coating, and the spray thickness is 45 mu m.
Performance testing
The mechanical properties (tensile strength, yield strength, elongation, reduction of area, impact energy, hardness) of the high pressure clamp prepared were tested with reference to ASTM A29/A29M-20. The test results are shown in Table 1.
TABLE 1
Claims (6)
1. The processing technology of the high-pressure clamp is characterized by comprising the following steps of: (1) blanking; (2) forging; (3) hot trimming; (4) forging inspection; (5) post-treatment; (6) inspecting the finished product; (7) paint spraying; (8) warehousing;
the blanking is to control the weight of a metal material to be 23.4kg, the metal material is a steel material, and the steel material comprises the following chemical components in percentage by weight: 0.38-0.43% of C, 0.75-1% of Mn, 0.15-0.35% of Si, less than or equal to 0.035% of P, less than or equal to 0.04% of S, 0.8-1.1% of Cr, 0.15-0.25% of Mo and the balance of Fe;
the forging comprises heating, flattening, pre-forging and final-forging, and the parameters of the heating are as follows: the heating voltage is 1050V, the heating beat is 25s, the heating temperature is 1150 ℃, and the final forging temperature is 950 ℃;
the specific steps of pre-forging and final-forging are as follows: pre-forging the flattened hot blank, placing the clamped pre-forged hot blank in the middle of a forging die cavity, and then starting forging, wherein forging parameters are 1.5s, so as to obtain a hot forging; the die staggering distance between the hot blank and the die is less than or equal to 0.5mm;
the processing technology of the high-pressure clamp is applied to the production of the clamp which is resistant to high pressure, medium corrosion, seawater and water mist.
2. The processing technology of the high-pressure clamp according to claim 1, wherein the slope of the blanking saw face is less than or equal to 2 degrees, the metal materials are placed in order, and steel nails of the material head and the material tail and flanging of the side edges are removed.
3. The process of claim 1, wherein the heating is performed using an intermediate frequency furnace, and the heated billet is hot.
4. The high pressure clip of claim 1, wherein the flattening comprises the steps of: after the hot blank is placed in the middle of the die and is stable, an air hammer is used for flattening the blank to 89-91mm.
5. The high pressure clamp of claim 1, wherein the post-treatment comprises: shot blasting, polishing, flaw detection and single treatment of 50-70 shot blasting machines, wherein the shot blasting time is 13-16min.
6. The process for manufacturing a high pressure clamp according to claim 1, wherein the paint is 100% paint on the surface, and the thickness of the paint is 10-35 μm.
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| CN202311103974.8A CN116810319B (en) | 2023-08-30 | 2023-08-30 | Processing technology and application of high-pressure clamp |
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| CN202311103974.8A CN116810319B (en) | 2023-08-30 | 2023-08-30 | Processing technology and application of high-pressure clamp |
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| CN116810319B true CN116810319B (en) | 2023-12-01 |
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| 孙传尧.《选矿工程师手册 第3册》.冶金工业出版社,2015,(第2015年03月第1版版),第706页. * |
| 张志文.《锻造工艺学》.机械工业出版社,1983,(第1983年05月第1版版),第376-377页. * |
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