Points to note when designing flanges

1. Tooling design and manufacture

The large flange is made up of two clamping base plates of 900, two flanged plates and two vertical plates and four reinforcing ribs. In order to ensure the rigidity of the tooling, the welded joints of the connected plates shall be welded through the groove, and the welding angle is 20-30 mm. A corresponding bolt hole is drilled in the flange plate to ensure that the flange can be accurately connected with the flange bracket, and a gap between the back end of the small end flange and the pallet can be placed in the small manual jack, and simultaneously A notch is formed in the flange plate in the direction of the vertical plate, so that the elbow can be loaded into the tooling, and the tooling with the groove structure can be made by the thick steel plate, which can meet the rigidity requirement during cutting.

2. Tooling performance requirements

The two flange faces of the large flange are perpendicular to each other, and the table of the vertical lathe is horizontally rotated, so the main function of the tool is to connect the tooling to the flange by bolt holes on the large end flange. . When the tooling is clamped on the workbench, ensure that the flange plane to be processed is concentric and parallel with the vertical lathe workbench. To reduce the number of tooling, the tooling should be able to change the clamping position to ensure that the bending can be processed on one tooling. Head 2 end size flange. At the same time, the tooling must have sufficient rigidity, otherwise it will seriously affect the processing quality of the flange sealing ring groove, so the height of the tooling should be reduced as much as possible under the use condition, which can improve the rigidity and facilitate the operation. The turning radius of the tooling and the large flange should not exceed the working radius of the vertical car, and the clamping can be easily adjusted to facilitate the cutting.

3. Tooling stiffness check

When the cantilever beam of the trough structure is subjected to bending and torsion under the force of turning, the deflection and the rotation angle should be verified. Through the above check, the maximum deflection of 7.27×lO-7m and the maximum angle of 8.969×10-5 are extremely small deformations, and the ribs are added in the relevant parts. The stiffness is far beyond the calculated value, and the stiffness can fully satisfy the cutting force. The requirement is that the maximum turning diameter of the tooling and the elbow flange is 2.42 m<3.50 m (two-column vertical turning diameter), so this tooling is theoretically feasible.

4. Turning processing

When processing large flanges, the bottom plate is adjusted downwardly and clamped on the vertical workbench. The elbow flange is installed in the manual assembly. The large end flange is fixed with the bolts to ensure the flange working surface and the vertical working. The table is concentric and parallel to cut. When processing the small end flange, the tooling bottom plate is downwardly mounted on the vertical working table. With 6 manual small jacks, the small end flange is bolted to the small end flange and the small end plate is tightened. The small flange can be cut with the small pallet, and the verticality of the size flange should be ensured when cutting and aligning the clamp.

The large-scale flange tooling structure is simple and reasonable, easy to manufacture, good in rigidity, easy to adjust and operate during processing, and fully meets the needs of the three sets of elbow flanges that are processed by the large elbow flange on the vertical car. Qualified, in the future without a face machining machine, the use of vertical lathe processing of similar components has opened up a new way.