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SMC 24002.2(24.MP.217 Part 1)

SMC 24002.2(24.MP.217 Part 1)
SMC 24002.2(24.MP.217 Part 1)

SMC 上汽汽车制造有限公司企业标准Enterprise Standard of S AIC Motor Manufacturing Corporation, Limited

SMC 24002.2-2006/MGR ES:24.MP.217 Part 1

上汽汽车标准化技术委员会发布

标题: 电弧焊– 设计和性能要求

共 8 页,第 1 页 日期:2004-04

内容:

1.工程设计要求

2.一般装配要求

3.性能要求

4.偏差

附件1 焊接缺陷检查表

备注:本标准必须同MG RES.24.MP.217 part 0一起使用。

1.工程设计要求

1.1一般设计要求

1.1.1焊接符号

以下给出的焊接符号代表了不同的焊接方式,设计工程师应根据需要来选择合适的焊接符合。

类型符号定义

普通焊接-+++++-这个等级涵盖了一般工程需要的焊接

定位焊接需要精确的定位

间断焊该焊接方式用于总成装配焊接中,在完全焊接之前预焊

对接焊主要用于表面之间连接的焊接方式

角焊将两块板材进行“T”字型的并具有适当角度的焊接

拐角和边缘焊接这种焊接方式是将两块板材连接形成成交角或者是凸缘

塞焊将加工件的一个组成部分连同焊丝填入预制的孔中,焊接后在孔所在表面形成了塔接的结构。

槽焊通过在一个组件的(长)孔中填充金属物使之和与之重叠的另外一个组件结合在一起。

点焊这种焊接方式是用焊点将一层或多层厚度的加工件表面重叠部分连接起来的焊接方式

下面是几个典型连接方式的图表:

图表1

T < 3.15mm 对接焊

T > 3.15mm

标题: 电弧焊– 设计和性能要求

共 8 页,第 2 页 日期:2004-04

W≤ 1.6mm

角焊

W=T/2 && W≤1.5mm

拐角焊

W=T/2 && W≤1.5mm T ≤ 6mm

边缘焊

W ≤T/2

T ≤ 2mm

塞焊

W(直径) ≥ 8mm T ≤3mm

槽焊

W ≤3T L ≤10T T ≤6mm

注:T为板料厚度

在图纸上每个焊接或者每批焊接均被个别标注,同时在“备注”中还统计了各种焊接方式所使用的次数。

标题: 电弧焊– 设计和性能要求

共 8 页,第 3 页 日期:2004-04

除非特别指出,否则所有焊接的连接长度可被认为整个连接长度,经特别指出的焊接长度会在图纸上标明。

除了对车身板材的材质和厚度进行规定之外,工程部门还要对焊接过程、焊接连接种类和焊接的边缘加工整理出一系列的要求。

工程部门还要对可达到的焊接能力和加工件不可避免的扭曲损坏进行预计。

实际有效焊接长度应为在图纸上标注的焊接长度的90%,这在生产中是可以被接受的。

焊点应避免出现在可以看见的区域中,如果不可避免,应选择准备喷涂涂层的表面以除去焊接的痕迹和溅污。

1.1.2

1.2 对接焊接

对接焊接的尺寸,也就是有效焊缝的厚度“t”被认为是进行焊接的两块板中最薄板的厚度。(图2)当对于 MGR ES.21.MP.200 系列的低碳钢进行对接焊接的时候,设计的最大啦伸和压缩力为147MN/m2,剪切力为108MN/m2。下表为对应于材料的各种厚度时,设计应力的大小。

表1-低碳钢对接焊接中的应力和焊缝厚度的关系

设计应力

有效焊缝厚度

mm

拉伸&压缩

N/linear mm weld

剪切力

N/linear mm

0.80 120 80

0.90 130 100

1.20 175 120

1.60 240 160

3.15 470 350

6.30 950 700

当对于MGR ES.21.MP.230 系列的铝合金进行对接焊接时,设计的最大拉伸和压缩力为38MN/m2,

剪切力为38MN/m2。下表为对应于材料的各种厚度时设计应力的大小。

表2-铝合金板料对接焊接时的应力与焊缝厚度的关系

设计应力

有效焊缝厚度

mm

拉伸&压缩

N/linear mm weld

剪切力

N/linear mm

标题: 电弧焊 – 设计和性能要求 共 8 页,第 4 页

日期:2004-04

0.80 32 20

0.90 37 24

1.20 49 29

1.60 65 39

2.00 75

51

1.3

角焊

通常除了正确的对应组件之外没有必要进行事先连接。在焊缝的任何地方,缝隙的宽度均不能大于零件厚度的一半(最薄的厚度)而且不大于1.5mm 。

角焊缝的尺寸为在凹角条件下所记录的以焊角长为腰的最大等腰三角形的高或者是1.4倍的实际焊缝厚度(图

2)。

Actual Throat Thickness

实际焊缝厚度

Design Throat Thickness

设计焊缝厚度

Leg Length 焊角长度

图表2

低碳钢角焊中最大允许的设计应力为147MN/m 2,而铝合金为40MN/m 2。

下表3和4给出了角焊中应力要求。

表3-低碳钢角焊应力要求

角焊尺寸(焊角长度) mm 设计应力

N/linear mm of weld

0.80 60 0.90 80 1.20 100 1.60 120 3.15 240 6.30 490

表4-铝合金角焊应力要求

标题: 电弧焊– 设计和性能要求

共 8 页,第 5 页 日期:2004-04

角焊尺寸(焊角长度)

mm

设计应力

N/linear mm of weld

0.80 16

0.90 21

1.20 26

1.60 31

2.00 42

1.4 低碳钢点焊和塞焊剪切应力

表5-低碳钢点焊和塞焊的剪切应力

焊接类型板料厚度(较薄板料)

mm

最小剪切应力

N

点焊0.80 2670

点焊0.90 3340

点焊 1.20 4890

塞焊 1.60 7120

塞焊 2.00 7560

塞焊 3.15 8900 应该避免有可能产生的熔接点焊,如果无法避免,熔接点焊可采用由较薄钢板向厚板料的焊接方式。

塞焊的板料厚度应在1.60mm~2.00mm之间,上表面的孔径应在8mm之内。板材厚度小于1.6mm 并且上表面孔径在8mm的塞焊,其最小的剪切应力应遵从焊接会议上所做的规定。

板材厚度大于2.0mm并且上表面锥形孔径最小为10mm的塞焊应该是最好的。通过设计的目的,应可得到最小剪切应力的50%。

当在镀锌板上进行熔接焊接时,可以预期焊接的多孔型。如下尺寸的延长孔也可以采用塞焊的方法。

<1mm的板料厚度6mm×12mm孔

≥1mm的板料厚度 7mm×12mm孔

1.5 偏差

本标准中所存在的任何偏差,在工程和装配工序工程师的确认后,如有必要可在图纸上标明所做的更改,并且此更改优先于本标准的要求。

2.一般装配要求

在装配操作中先于完全焊接的间断焊接并不被认为时最终的焊接,而且必须被除去或者是重新焊接。

应尽可能的避免出现的间断焊接。

2.1 任何部门都可对图纸、标准或是工艺计划过程中存在的问题提出质疑,但最终的修改权利在工程部

门。任何疑问需备有详细的说明文件而且须给出每个相关部门发放修改流程卡片。

标题: 电弧焊– 设计和性能要求

共 8 页,第 6 页 日期:2004-04

3.性能要求

3.1操作工人和焊接工人训练

3.1.1 在正式上生产线之前,操作工应进行适当的焊接设备、机械自动化焊接和原材料的培训。经过培训后,他们应该能生产出符合要求的零件并达到ROVER集团所批准的焊接员训练计划的要求。 3.1.2 为了保证焊接质量的稳定性,在生产流程中焊接工须生产出令人满意的样品,同时装配需要以适当的节奏进行。综合考虑,正确的工作方式可以作为检验标准,并注意那些不符合操作规范的焊接方式。

3.2可接受的最低焊接要求

整个底部和侧边完全熔接;

最小的渗透必须定义。

3.3焊接偏差定义

如果出现下面的情况则认为焊接有缺陷:

a)焊点周围基材碎裂或者焊点碎裂;

b)熔接不完全,孔过多,火口裂纹,或者熔接粘附(见附录1);

c)底切不能超过基材厚度的15%(见附录1);

d)焊接工序会导致过多的弯曲。直线折旧法不能正常的被实行。

e)实际有效焊接的长度不得小于规定长度的90%。有缺陷的中断和起始处并不计算到焊接长度上

去(见附录1);

f)焊接点没有按照相关的图纸规定的定点,除了得到允许的更改和偏差。

4.偏差

4.1偏差

本标准中所存在的任何偏差,在工程和装配工序工程师的确认后,如有必要可在图纸上标明所做的更改,并且此更改优先于本标准的要求。

附录1 有缺陷的焊接问题汇总图I

有缺陷的焊接问题一览。

标题: 电弧焊– 设计和性能要求

共 8 页,第 7 页 日期:2004-04

图表1

符合要求的焊接

图表2

有缺陷的焊接

图表3

气孔

图表4

多孔

标题: 电弧焊– 设计和性能要求

共 8 页,第 8 页 日期:2004-04

图表5

烧穿

图表6

图表7

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