Main processing technology

Raw materials into the factory (reinspection) → cutting into billets → heating and pushing into shape → shaping → Heat treatment → machining groove → surface treatment → finished product inspection → identification protection → storage(Note: There is a pickling passivation process for stainless steel products before surface treatment)

Specification and model

DN10-DN3000 90° and 45° long radius and short radius, and heating furnace pipe elbow accessories and other customized production according to customer standards

Standard

National standard, American standard, German standard, Japanese standard and other customized production according to customer standard requirements

Black, yellow, blue, red and other customized production according to customer standards

Main equipment and installation

1: hydraulic pushing machine, the maximum thrust of 440T, mainly push DN250 pipe fittings

2:set of screw mechanical pushing machine, the maximum thrust is 160T, mainly pushing pipe fittings below DN200

3: One medium frequency heating equipment, 250KW (Hangkai), the highest heating temperature 1200℃

4: one medium frequency heating equipment, 160KW (Hangkai), the highest heating temperature 1050℃

5: Machining equipment: Lathe D620-1 TX50 Power head lathe: JT250 TX50 TX63A lathe 16K40 boring machine T6112 lathe CQ61100

6: Heat treatment furnace (trolley type box type resistance furnace) RT9-80*1500*60, the highest furnace temperature 1200℃

7: Sand blasting machine 2 sets: mainly used for pipe surface rust removal

8: Sensor (homemade) : 60 sets for material heating

9: Push core head (self-made) : 126 sets for forming guarantee

10: Air compressor: used for heat treatment air cooling

11:76 sets of machining fixtures (special)

12:355T hydraulic press 1 set (mainly used for elbow shaping)

1. Acceptance of raw materials

1. Raw materials shall meet the requirements of relevant standards or technical specifications.

2, the surface of raw materials should be free of oil, excessive rust corrosion and obvious dent defects, low melting point metal pollution.

3, check the quality certificate of raw materials, furnace number, batch number, specifications, manufacturers and implementation standards.

4, raw materials with steel wire brush for mechanical rust removal, so that it meets the requirements of non-destructive testing.

5, the raw material size test (length, width, thickness and steel pipe irregularity).

6, the steel pipe and steel plate after entering the factory should be ultrasonic reinspected, grade I is qualified.

7, physical and chemical testing, the steel pipe and steel plate into the factory according to the furnace batch number, specifications for chemical element analysis, mechanical properties, hardness test, test results should meet the requirements of raw material standards.

8, after re-inspection according to the factory regulations for serial number registration.

Ii. Manufacturing process

① Material selection, elbow selection of appropriate steel plate or steel pipe, use template marking with oxyacetylene flame or saw cutting, and the raw materials of the furnace, batch number and pipe specifications, project name, number clearly marked.

② The steel plate is rolled and welded.

③ Load the required mandrel into the pushing machine with the crane, further clean the billet, coat the inner wall with graphite, and then install on the push rod (according to the length of the billet can be installed multiple at a time), lock the mandrel with the insert plate, and preheat the internal mold to the appropriate temperature for pushing (heating temperature and advancing speed should be the best match).

④ Adjust the intermediate frequency heating ring, the tube blank heating to the required temperature, control the advance speed.

⑤ Buckle the bend, and correct the curvature radius of the formed elbow with a suitable birthgear on the hydraulic press.

6 To the end, according to the specifications of the elbow with the appropriate gear on the bevel machine to find the right, and then fixed the cutting gun, cut off the excess billet, and leave a processing margin for the mouth.

⑦ Integer, with a special birthgear clamping elbow, with a prop head in the press for port integer.

4. Heat treatment: According to the heat treatment process, the elbow is put into the furnace for heat treatment.

5. Surface treatment: The pipe fittings after heat treatment will be removed by sandblasting machine.

6. After the surface treatment, the elbow weld is tested by 100% ray, which is qualified in class II.

7. Mechanical properties testing: According to the relevant standards, the mechanical properties of the elbow after production are tested to ensure that the mechanical properties of the elbow after production are up to standard, and the testing items and sampling orientation should meet the requirements of the relevant standards.

8. End machining: mechanical end machining groove according to the design confirmation drawing. Within 50mm from the end of the pipe, the residual height of the internal and external welds shall be grinded by an Angle grinder.

9. Appearance inspection

① There should be no cracks and other phenomena after the production of the elbow, and there should be no hard points on the surface.

② Any defects on the pipe body after the production of the elbow are not allowed to be repaired by welding.

10. Size inspection: The relevant inspection personnel of the company shall conduct size inspection according to the relevant standard requirements of drawings and pipe fittings, and meet the tolerance requirements.

11. Surface treatment: The inner and outer surfaces of the elbow after production should be smooth, without damaging strength and appearance defects, such as scars, scratches, heavy skin, etc., should be repaired after defects are found, and the thinning amount at the grinding place should not be less than 93.5% of the original wall thickness, and the grinding place should be smooth and verified by colorant or magnetic powder inspection until the defects are removed.

12. Non-destructive testing of elbow after production

After the heat treatment of the elbow after production, the company holds the relevant qualification certificate personnel, according to the standard requirements of the elbow magnetic powder, ultrasonic, test results reached the grade I qualified.

13. Logo

Marked with a stencil brush or low stress impression, the outer wall is clearly marked with the standard requirements in order.

14. Stacking and transportation of elbows after production

The elbow can not be in contact with any part of the carriage during transportation to avoid bumping.

Product after-sales service commitment