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Design of equipment for welding head path correction
Benáček, Filip ; Jaroš, Aleš (referee) ; Slaný, Martin (advisor)
The work presents the problem of welding of membrane walls intended for application in power boilers. Furthermore, the use of the MIG/MAG method for welding and the advantages of using the CMT method. An innovation has been made for the welding process in the form of laser scanning of the surface and subsequent use of the data to correct the welding head. This led to the automation of the whole process. Because of the necessary testing of the laser scanner function, a test structure was designed and constructed. It was necessary to consider the appropriate wall scanning strategy and subsequent data processing in terms of the overall manufacturing process. The software designed to evaluate the scanned profile placed a point using a suitable tool on the scanned profile. The set of points was further filtered for a smoother resulting path formed by these points. The resulting points were fed to the output signal from the laser device to correct the path of the welding head. Both the welding and the surface scanning will be done simultaneously, so the settings for the laser scanner were created and stored in the internal unit of the device. This allows the laser to operate without connecting to a computer.
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Numeric simulation of the turbine rotor surfacing
Durajová, Věra ; Slováček, Marek (referee) ; Daněk, Ladislav (advisor)
The project elaborated in frame of engineering studies, solves the problem of restoration of the damaged hinge groove blades, and the surfacing of cylindrical faces of the SAW method, using additional material TOPCORE 838 B. The turbine rotor is made from steel with high resistance temperature 30CrMoNiV5-11. Based on literature studies and issues surfacing calculation, it was established that will preheat the material. The issue was solved by using simulation program SYSWELD.
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Renovation of wood flaker rotor blades by flux cored wires
Soldán, Jan ; Kubíček, Jaroslav (referee) ; Sigmund, Marian (advisor)
The bachelor thesis presents a state of renovation of wood flaker rotor blades by flux cored arc welding. The theoretical part of the thesis presents posssible ways of renovations with materials included. Subsequently, in order to find out, which one of two flux cored electrodes are more suitable for this specific renovation, the experiment was made. The flux cored electrodes were compared in heat input, price, micro and macro structure and final hardness of welded material. Due to very high hardness results, the flux cored electrode named Megafil A760M was chosen to be used in the renovation. At the end of the thesis, the specification of welding process was according to EN ISO 15 609-1 standard.
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Minimalizace abrazivního opotřebení pomocí tvrdokovových návarů u zemědělských strojů
Bednář, Štěpán
The preparation and processing of land is the primary process in agricultural practice, which leads to the provision of the basic needs of mankind. The operation of racks and machine parts is exposed to negative aspects in these conditions. Tribological influences associated with operation have an impact on the mechanisms of functional parts and cause their abrasive wear. This work deals with the minimization of abrasive wear using carbide welds. Detailed information on the mineralogical properties, size and shape of abrasive particles is summarized in the theoretical part. The chapter also describes the types of materials, heat treatment and welding technology. After that, the characteristics of agricultural machines and machine parts with increased intensity of abrasive wear and methods of renovating parts are described. The experimental part describes the preparation of samples by the fusion welding method and the analysis of the weight loss of the material on the sanding cloth. Using the results, the mechanical properties of the applied carbides are then evaluated.
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An effective cutting tool for shearing of spring wires
Smékal, Jan ; Sliwková, Petra (referee) ; Píška, Miroslav (advisor)
The goal of this master thesis was to propose modification of a cutting tool for shearing of spring wires with focus on improving its lifetime. An analysis of cutting process was made which confirmed low lifetime of lower cutting tool – average lifetime of cutting tool is 3 734 pieces. Suggestions were made in the thesis such as change of current technology, change of material of cutting tool or local change of cutting edge of the tool. Three changes were designed – insert from sintered carbide, hardfacing welding of the cutting edge and insert from high-speed steel. Testing of sintered carbide inserts ČSN ISO 513 HC – P80 and ČSN ISO 513 HC – P60 showed that sintered carbides are too brittle for cutting spring wires. Five hardfacing welding materials (HS6-5-2, HS2-9-2, X37CrMoW5-1, Stellite6 and Stellite12) have been tested. Material X37CrMoW5-1 had the best lifetime results with lifetime of 2 463 pieces. This material was further tested and average lifetime achieved was 2 021 pieces. However, there was decrease of hardness in a heat-affected zone. The last change of cutting edge was an insert from high-speed steels HS12-1-4 and HS10-4-3-10. These inserts were broken prematurely at the soldered joint and both high-speed steels exhibited cracks due to high material hardness (60 and 65 HRC), very low toughness at extremal loading.
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Replacement of nickel alloy overlay by manganese alloy overlay
Hlobil, Albert ; Kubíček, Jaroslav (referee) ; Sigmund, Marian (advisor)
The thesis is focused on the issue of tuning the welding process of the 18.8. Mn alloy using the method 152. The welded component is the cylindrical throat of a Venturi tube made of ASME SA-106 Grade C carbon steel. A series of welds were performed, which were qualitatively evaluated and compared. Metallographic sections were made, and the dilution, excess, and width of the heat-affected zone were determined. Evaluation of microstructure and microhardness were also performed. Based on the tests performed, suitable welding process parameters were used. For comparison, a test for chemical and salt mist corrosion was undertaken, where the corrosion resistance of the 18.8. Mn alloy weld was compared to Inconel 625 alloy.
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Analysis of Inconel 625 weld layer produced by MIG-CMT
Chrást, Daniel ; Slováček, Marek (referee) ; Kubíček, Jaroslav (advisor)
Návary z materiálu Inconel 625 na základní materiál 16Mo3 slouží v energetickém průmyslu u spaloven odpadu pro zvýšení životnosti membránových stěn. Návarové housenky jsou vytvořeny pomocí metody MIG-CMT. Byly provedeny analýzy makrostruktury a mikrostruktury za použití SEM mikroskopu Apreo 2, dále byla provedena analýza chemické složení návarové housenky za použití OES spektrometru ISpark. Nakonec byly provedeny analýzy vybraných mechanických vlastností, konkrétně mikrotvrdost a tažnost.
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Nickel alloy overlay welding parameters optimalization
Lauš, Lukáš ; Kubíček, Jaroslav (referee) ; Sigmund, Marian (advisor)
The aim of these master's thesis is to choose and optimize parameters of the Venturi tube throat weld cladding. The Venturi tube is made from carbon steel ASME SA-106 Grade C. The weld cladding is performed by plasma transferred arc welding. The throat is weld overlaid with nickel base powder Inconel 625. The overlays are made without oscilation. The main requirement was to find a maximum possible powder feed rate and others welding parameters to develop maximum welding speed and productivity on automat. Visual and penetrant testing on the overlays were performed. Metalographic samples were prepared. On the samples was meassured dilution, overlay thickness and width of the heat affected zone. Results are compared with parameters succesfully used in the cooperating company.
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Design of equipment for welding head path correction
Benáček, Filip ; Jaroš, Aleš (referee) ; Slaný, Martin (advisor)
The work presents the problem of welding of membrane walls intended for application in power boilers. Furthermore, the use of the MIG/MAG method for welding and the advantages of using the CMT method. An innovation has been made for the welding process in the form of laser scanning of the surface and subsequent use of the data to correct the welding head. This led to the automation of the whole process. Because of the necessary testing of the laser scanner function, a test structure was designed and constructed. It was necessary to consider the appropriate wall scanning strategy and subsequent data processing in terms of the overall manufacturing process. The software designed to evaluate the scanned profile placed a point using a suitable tool on the scanned profile. The set of points was further filtered for a smoother resulting path formed by these points. The resulting points were fed to the output signal from the laser device to correct the path of the welding head. Both the welding and the surface scanning will be done simultaneously, so the settings for the laser scanner were created and stored in the internal unit of the device. This allows the laser to operate without connecting to a computer.
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Digital commissioning of a robotic production system for resistance welding
Šuba, Marek ; Bražina, Jakub (referee) ; Vetiška, Jan (advisor)
The subject of this diploma thesis is the simulation and digital commissioning of a robotic production system for welding elements such as studs on sheet metal parts. The basis of the work is search of information related to industrial robots, PLC control, tools used for welding, fixtures, manipulators, sensors, safety and protection elements commonly used in such production systems. The second part of the work deals with the given problem and it is a virtual commissioning of the given concept of a robotic production system. This means creating its simulation model in the Process Simulate environment, selecting robots, creating robotic trajectories, collision analysis, creating sensors, signals and optimization. Last part includes the connection of the simulation model with the software S-7PLCSIM Advanced and TIA Portal, the creation of control PLC logic in the form of a program, visualization and verification of their functionality using the above-mentioned connection with the simulation model.
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