Manufacturing Instructions

Transcription

1 May 2016 Manufacturing Instructions Thermal cutting and bending SN ICS Dimensions in mm Supersedes SN 200-3: Table of contents Page 1 Scope Normative references Terms Thermal cutting Cut surface quality Locations of the measuring points Mean height of the profile Geometrical lerance Bending Bending of flat products Cold bending of pipes Inspection... 7 Referenced technical standards, codes and regulations... 7 Revision of May Scope This company standard specifies the requirements for parts produced by thermal cutting or by bending and used for the manufacture of SMS group products. 2 Normative references The documents listed below are required for the application of this standard. Dated references refer only the edition of the date indicated. Undated references refer the latest edition of the respective document inclusive of all revisions. SN SN Manufacturing instructions; Requirements and principles Manufacturing Instructions - Welding 3 Terms The following terms and definitions shall be used for the application of this document. Pipes (DIN EN 10079: ) Long products of circular or square section which are open at both ends. NOTE for SMS group: Pipes are semi-finished products which have not undergone machining and which are delivered the site by the meter for further preparation for the use as pipe lines. Pipe line (SN 696: ) A rigid unit of the pipework made up of various piping components. Number of pages: 7 Edited by: SMS group Standards Office SMS group GmbH 2016 "The present document is protected by copyright. Reproduction, distribution and utilization of this document as well as communication of its contents others are prohibited unless expressly authorized by us. Any violations will be prosecuted under criminal law and will result in an obligation pay damages. All rights reserved."

2 Page 2 4 Thermal cutting 4.1 Cut surface quality The cut surface quality is the distance between two parallel straight lines between which the cut surface profile lies within the theoretical angle (e.g. 90 for a vertical cut). The perpendicularity or angularity lerance includes both the straightness and the flatness deviations. Figure 1 (vertical cut) and figure 2 (bevel cut) show the maximum actual-value deviations within the lerance class. 4.2 Locations of the measuring points The perpendicularity and angularity lerance u indicated in table 2 shall be complied with and shall be determined in a limited area of the cut surface. On account of the melting at the p edge of the cut, the cut face shall - according figures 1 and 2 - be reduced from the p and botm cut face edges by the dimension a as in table 1. Examination area Fig. 1 Vertical cut Examination area Fig. 2 Bevel cut Table 1 Dimensions for a Cutting thickness a a 3 0,1a > 3 6 0,3 > ,6 > > ,5 > > > > > The values up 300 mm correspond those in table 3 of DIN EN ISO 9013: Values > 300 mm are SMS group specific. Table 2 - Perpendicularity or angularity lerance Cutting thickness a Up 20 >20 40 >40 60 >60 80 > > > > > > > > > > > u , Values up 140 mm correspond those in section 4 of table 4 in DIN EN ISO 9013: , values >140 mm are SMS group specific.

3 Page Mean height of the profile The mean height of the profile R Z5 according DIN EN ISO 9013 is the arithmetic mean of the single profile elements of five adjacent individual measurements; refer figure 3. The values in table 3 shall be observed. Legend l n sampling length Z t1 Z t5 single profile elements l r single sampling length (1/5 of l n) Fig. 3 Mean height of the profile Table 3 Mean height of the profile Cutting thickness a Up 20 >20 40 >40 60 >60 80 > > > > > > > > > > > R Z Values up 140 mm correspond those in section 4 of table 5 in DIN EN ISO 9013: , values >140 mm are SMS group specific.

4 Page Geometrical lerance Figure 4 shows the maximum permissible actual-value deviations within the lerance zones. The drawing dimension shall be taken as the nominal dimension. The actual dimensions shall be measured on the cut surfaces after cleaning. The limit deviations for nominal dimensions stated in table 4 apply dimensions without lerance indication. The limit deviations correspond lerance class 1 according DIN EN ISO 9013: Lateral view b) View Legend t G1 t G2 straightness lerance (see DIN EN ISO 1101: , 18.1) for cutting length; straightness lerance (see DIN EN ISO 1101: , 18.1) for cutting width; t w perpendicularity lerance (see DIN EN ISO 1101: , 18.10) for cutting width related A; t p U parallelism lerance (see DIN EN ISO 1101: , 18.9) for cutting width related A in plate plane; perpendicularity lerance (see DIN EN ISO 1101: , 18.10) in cutting beam direction; Fig. 4 Form and location lerances (shown in two views of a sheet)

5 Page 5 Table 4 Limit deviations for nominal dimensions Nominal dimensions Workpiece thickness > 0 < 3 3 < < < < < < < 4000 Limit deviations > 0 1 0,04 0,1 0,1 0,2 0,2 0,3 0,3 0,3 > 1 3,15 0,1 0,2 0,2 0,3 0,3 0,4 0,4 0,4 > 3,15 6,3 0,3 0,3 0,4 0,4 0,5 0,5 0,6 > 6,3 10-0,5 0,6 0,6 0,7 0,7 0,7 0,8 > ,6 0,7 0,7 0,8 1 1,6 2,5 > ,3 1,3 1,4 1,7 2,2 3,1 > ,9 2 2,1 2,3 2,9 3,8 > ,6 2,7 2,7 3 3,6 4,5 > ,7 4,2 5,2 > ,4 4,9 5,9 Values up 300 mm correspond those in table 6 of DIN EN ISO 9013: Values > 300 mm are SMS group specific. 5 Bending 5.1 Bending of flat products For the bending of flat products, the permissible bending radii and leg lengths as in figure 5 and table 5 shall be complied with. In the cold bending of flat products, the values of table 5 apply only steel grades with a minimum tensile strength of R m 390 MPa. Further specifications can be found in DIN 6935: Fig. 5 Arrangement for bending Table 5 - Bending radii and leg lengths for a bending angle of 90 Plate gauge s Bending radius min. r Leg length min. l

6 Page Cold bending of pipes Cold bending of pipes shall be preferred the use of welding elbows. If drawings show welding elbows which can be replaced with cold-bent pipes when taking in account the larger bending radii, the manufacturing workshop is free use the cold-bent pipe. When pipes are shown on isometric drawings, compliance with the drawing indications shall be ensured Bending radii Bending radii for cold-bent pipes are specified in Table 6. For cold-bent pipes, a roundness deviation of 4% according DIN EN : is permissible. For inductively (hot) bent pipes, the permissible roundness deviation is 2,5%. The roundness deviation of a pipe is calculated with the following formula (Fig. 6): 2( d a d a ) x100 U ( d a d a ) Fig. 6 Roundness deviation Table 6 - Bending radii of pipes Pipe outside diameter Bending radius 6 12 Min. 2 x outside pipe diameter for wall thicknesses >1,0 > Min. 2 x outside pipe diameter for all wall thicknesses > 48, Min. 2.5 x outside pipe diameter for all wall thicknesses General lerances The general lerances are specified in Table 7 according DIN EN ISO 13920: These general lerances correspond the welding lerances and shall be applied bent parts by analogy. Tolerance category B according table 7 applies completely dimensioned pipe lines (e.g. pipe detail, isometric drawing) and workpieces produced by bending of flat products; lerance category C according table 7 applies not completely dimensioned and freely laid pipe lines. Linear dimensions are be undersod as outside, inside, and stepped dimensions, bending diameters and bending radii. Tolerance category 2 30 > Table 7 Tolerances on linear dimensions > > Nominal dimension range > > > > > > > B C General lerances for angular dimensions The general lerances for angular dimensions are specified in SN 200-4:

7 Page 7 6 Inspection Flame-cut and bent parts shall be checked by the manufacturer for compliance with the specified dimensions and angles. The manufacturer shall also inspect the surface quality (height of the profile R z5) of flame-cut faces. Documenting of the inspections is not required. Referenced technical standards, codes and regulations DIN 6935: DIN EN : Cold bending of flat rolled steel Metallic industrial piping - Part 3: Design and calculation DIN EN ISO 1101: DIN EN ISO 9013: Geometrical product specifications (GPS); Geometrical lerancing; Tolerances of form, orientation, location and run-out Thermal cutting - Classification of thermal cuts; Geometrical product specification and quality lerances DIN EN ISO 13920: Welding - General lerances for welded constructions - Dimensions for lengths, and angles, shape and position SN 200-4: SN 696: Manufacturing Instructions; Welding Piping support Revision of May 2016 Edirial revision. Section 2 Normative references added Section 3 Terms added Section. 4.2 Revision refers only the German version. Table 1: Footnote added Section 4.4 Table 4: Footnote added Section Roundness deviation of cold-bent pipe revised max. 4%; roundness deviation of hot-bent pipe added; Figure 6 and formula for calculation of roundness deviation added.