Lecture 3-2: Hull production Steel processing methods

Transcription

1 Kul Shipyard engineering Lecture 3-2: Hull production Steel processing methods Applied Mechanics Marine Technology

2 Lecture in course contents Production planning Introduction Shipbuilding process and ship yard productivity Outfitting Design process and materials management Hull production

3 Objectives, contents and literature Learning objective: Understand the main manufacturing methods used in block and hull production Know the equipment used in material handling and transporting Contents: Cutting methods Plate and stiffener bending Welding processes Material handling Literature Laivatekniikka. Räisänen toim., 2000 Ship production, Storch et al., SNAME, 1995

4 Cutting methods The aim if parts cutting, but also the beveling and groove manufacturing Thermal cutting processes Flame cutting Plasma arc cutting Laser beam cutting Thermal cutting machines Small flame cutting machines Parallel cutting machines NC controlled cutting machines Mechanical cutting methods and machines Water jet cutting Press shears Disk shear Milling

5 Comparison of cutting methods Measures for comparison: Productivity Accuracy Distortion Plate thickness Groove manufacturing and beveling Cutting of openings Environmental impact

6 Forming methods Thermal forming (line heating) Rolls Bending press Press Press brake Frame benders Flame straightening Roll-straightening

7 Forming methods Thermal forming (line heating) Rolls Bending press Press Press brake Frame benders Flame straightening Roll-straightening

8 Forming methods Thermal forming (line heating) Rolls Bending press Press Press brake Frame benders Flame straightening Roll-straightening Gap press Press brake

9 Forming methods Thermal forming (line heating) Rolls Bending press Press Press brake Frame benders Flame straightening Roll-straightening

10 Forming methods Thermal forming (line heating) Rolls Bending press Press Press brake Frame benders Flame straightening Roll-straightening

11 Welding processes Arc welding process MIG/MAG-metal arc welding Gas-shielded metal arc welding (GMAW) Metal inert gas welding (MIG) Metal active gas welding (MAG) Flux cored arc welding (FCAW) Electro gas welding (EGW ) Submerged arc welding (SAW) Electro slag welding (ESW) Shielded metal arc welding (SMAW) Other welding process Friction Stir welding Laser-hybrid welding Butt weld Fillet weld

12 MIG/MAG and flux cored arc welding (FCAW) MIG/MAG The arc between the filler and parent metal Active or passive shielding gas Flux cored arc welding FCAW A hollow filler wire with flux The most important and common welding method in ship building Suitable for various materials and all welding positions

13 Electro gas welding EGW EGW is a development of electroslag welding Welding in mold Single pass welding for thick plates Mainly used for Vertical seam in shell plates Tanker s bulkheads

14 Submerged arc welding SAW The metal arc welding, where the molten weld and arc zone are protected by granular composition Typically automatized Rail, tractor Mainly used for: Butt joint between plates Joint between web frame and deck plate Web-flange joint in T- beams

15 Electro slag welding ESW Fusion welding method, in which a current passes through the slag layer Mainly used for: I-beam of tankers deck structure

16 Shielded metal arc welding SMAW Manual metal arc welding, where the arc is between the electrode and metals to be joined The electrode coating forms a protective gas FCAW replaced in the 1980s Currently used: Outside, in all-weathers Tanks far away from power supply

17 Friction Stir Welding Rotating tool causes the frictional heat that joins the work pieces in the joint area and the tracks are interconnected In shipbuilding, friction stir welding is used for the manufacturing of aluminum decks Joining of the extruded profiles together resulting in deck plate with stiffener

18 Laser-hybrid welding A relatively new welding process, in where the MIG or MAG welding is combined with laser welding Both the laser and MAG is involved in the melting process, resulting in a narrow weld Significantly less heat input than traditional arc welding Currently used: In panel line for butt and fillet welds SAW Hybrid See INTERSHIP - Video

19 Laser-hybrid welding

20 Advantage of Laser-hybrid welding Laser-hybrid welding offers advantages over conventional arc welding processes Lower heat input and lower welding deformation Higher welding speed i.e. productivity Allows thin plate (T < 5.5 mm) welding in shipyard environment... but, investment cost for equipment are still relative high Arc welded deck Laser-hybrid welded plate

21 Material handling Conveyors roller, chain and disk Bridge and gantry cranes Lifting hook, clamp, magnetic, vacuum Radio or cable control, cab

22 Material handling Cages Trucks Transfer platforms Loading trailer

23 Material handling Block truck Air bearings Walking beam type of transfer beams Runner and transferring jacks