1. Fabrication of inner skeleton
①According to the stone carving model, the required height is calculated in proportion, and the square cage is welded from thick to thin, from dense to sparse.
②Before welding, in addition to checking the flatness of the cut, for pipes with a wall thickness greater than or equal to 4mm, the pipe end should be processed with a V-shaped groove, and the pipe groove should have a groove gap as required. All load-bearing skeletons are fully welded on both sides, and the overall skeleton is fully coated with anti-rust paint three times after completion.
③Main bracket design
(1) The main load borne by the main support
1) The weight of the main support, auxiliary support, bronze wall panels and other accessories.
2) Steady-state wind load. Under the selected wind speed, the wind force in all directions acting on the stone sculpture from the front, side, back, and other four aspects is generally considered. In order to improve the safety of the structure, an amplifying system must be added to the calculated actual weight and wind speed for the design of the main and auxiliary supports. The size of the magnification factor is different for each stone sculpture, because the wind speed, temperature difference, and structure of the stone sculpture itself are different in different places. The former two should be selected from the local statistical data over the years; The ratio of the height to the diameter of the bottom surface is considered: the wind load can be calculated according to the selected wind speed, and then confirmed by the data of the model wind tunnel test measurement point.
(2) The shape and size of the main bracket
The design of the outline shape and size of the main bracket is measured with a 1:5 mid-sample model. Starting from the bottom plane, take a point at the intersection of the cross-section of the vertical Z-axis and the outline of the
Stone Carving, and measure its plane coordinates . The number of points to be taken should be based on the curve that can accurately draw a full circle of contour shape on this section. The measured coordinates of each point are multiplied by 5 to obtain the plane coordinates of the 1:1 full-scale image. The distance between the cross-sections on the Z axis is 0.5 (1:1 value), and the spatial coordinates of the entire stone sculpture can be obtained by measuring upwards layer by layer. Then make the shape of the main bracket similar to that of the stone carving, and leave a gap of 0.5~1.0m between the two, so that the shape and size of the main bracket are determined.
(3) The form of the main bracket
Sectional steel welding main frame: using channel steel, angle steel and other profiles, welding to form the main support. It has good rigidity and strength, and it is relatively easy to manufacture and install. Most of them are difficult to accurately measure the geometric shape. During the installation process, there will often be collisions between the main bracket and the copper wall panel. However, the shape of the stone-carved copper siding is not allowed to be changed, only the main bracket can be modified.
(4) Auxiliary bracket height gauge
The shape of stone sculpture is often irregular, the outer shape of the main bracket cannot be made exactly the same as the shape of the inner cavity of the stone carving, and the copper wall board cannot be directly hung on the main bracket. And the load on the copper siding must be transferred to the main support and let it bear. The expansion coefficients of steel and copper alloys are different, and when the ambient temperature changes, the expansion rates of the two will be different. If it is a rigid edge connection, there will be a huge tensile and compressive stress between them, which is enough to destroy the copper wall panel. At the same time, the temperature difference between the direct sunlight and the shady part of the tall outdoor cast copper stone sculpture can reach more than 10 degrees Celsius, and the copper siding will cause a large temperature difference stress, especially the copper siding The weld zone between them is very sensitive to temperature difference. In addition, the actual installation stress also requires a certain free compensation margin between the two to eliminate or reduce these stresses and ensure the safe use of the structure. The above requirements must be solved by rationally designing the auxiliary bracket.
In the design of the sub-support structure, a single piece of copper wall plate is often used as a separate body, and a lug is cast on the wall plate to connect with one end of the sub-support, and the other end of the rod is connected to the main support.
In order to transfer the load on the copper panel to the main bracket by the auxiliary bracket, the number and position of the lugs on the copper panel, the space angle formed by the connection between the sub bracket and the main bracket, etc. should be based on the fact that they can form a super The static structure prevails. The higher the degree of static indetermination of the structure, the more reliably the load on the copper siding can be transmitted to the main support without being transmitted to the next layer of copper siding. Otherwise, the stress generated by the lower layers of copper wall panels supporting the upper layers of copper wall panels will exceed the allowable range, resulting in plastic deformation or damage to the wall panels. In addition, the auxiliary support structure itself should have a certain degree of toughness, have an appropriate free expansion and contraction margin, and protect the safe operation of the copper panel.
2. Manufacturing process of Stone Garden Decor
① is the cutting material. Generally, the tool used is electric scissors, which can cut thin plates below 2mm, but the flatness is not good after cutting. There is also a cutting machine, which can cut both thick and thin plates, but it can only cut straight lines, and there is nothing to do when encountering arcs. If you want to cut the stone garden decorative sheet into flat and various shapes, you need to use a plasma cutting machine. Plasma cutting machines can use high plasma to cut metals that are difficult to cut with ordinary oxygen cutting methods. Because the current and gas are fed into the water-cooled special nozzle, a strong compression arc is formed to form a plasma flow with extremely high temperature (above 10,000 degrees), so the cut stone garden decorative sheet is neat and does not deform. Note that the hand must be steady when cutting the material, otherwise the material will be cut. After the material is cut, it must be planed according to the shape required by the work. Don't leave flaws on the surface of the board, so as not to leave defects after the work is polished.
② It is a method of making carbon steel plate stone sculpture and Stone Garden Decor. The carbon steel plate and stone garden decorative board are not knocked on the mold, but according to the different shapes of each part of the plaster model, the material is knocked out according to the ups and downs of the plaster model, and the bending is done consciously. Knock the edge where it should be, and you can knock it on any tangible and solid object, and then take the knocked stone garden decorative board to the mold for comparison, and think that the shape is correct and can be completely closed with the model, and then put these scattered pieces Carbon steel plates and Stone Garden Decor are welded piece by piece from top to bottom, and each piece must be adjusted against the mold. The texture effect of the surface of each Stone Garden Decor plate must remain the same, which must be forged while making the shape. system up. You can also forge the points first and then cut the material. When forging points, use the round head of the hammer to forge evenly and regularly in rows. The width and distance and force should be the same. Don't knock randomly, otherwise it will destroy the overall sense of the stone carving.
③ After the shape is forged correctly, they must be welded together according to the requirements of the work (including electric welding and argon arc welding). For electric welding, electric welding machine, welding handle and welding rod should be prepared. Due to the high degree of light generated during welding, it is highly irritating to the eyes, so wear a protective cover to avoid being injured by strong light. Welding with electric welding, the stone garden decorative plate will be deformed to a greater degree when exposed to heat, so some measures should be taken, such as spot welding first or cooling while welding. Argon arc welding is superior to electric welding. It is a gas-shielded arc welding method. Argon gas is used to protect the metals melted by the arc at the joints to avoid the harmful effects of oxygen and nitrogen in the air. Argon arc welding can be divided into melting electrode argon arc welding, non-melting electrode arc welding or tungsten argon arc welding according to the different electrode materials used. In stone garden decorative welding, tungsten argon arc welding is commonly used to obtain excellent welding quality. Because it is not easy to conduct heat, the deformation of Stone Garden Decor is relatively high.
④Carbon steel plate and Stone Garden Decor polishing First, use a grinding wheel to smooth the weld seams and excess areas of the work, and then use a soft wheel (cloth wheel) for polishing. When polishing, the work is coated with polishing paste to increase lubrication, so that the work can be polished It comes out brighter, which gives people a good visual aesthetic feeling.
