Manufacturing of steel doors by gluing. Equipment for the production of steel doors on an automatic line and manually

Metal doors are deservedly popular products. Users have long appreciated their practicality, reliability and durability. Modern designs are distinguished by attractive design and ease of use.

Russian companies supply the market with a huge range of similar products, characterized by high performance qualities combined with decent burglary resistance. The latter property is provided by many factors, including the type of metal structure, locks and material thickness.

Entrance doors from Russian production regularly receive excellent user reviews for heat and sound insulation.

Advantages of steel entrance doors

The demand for them is due to many reasons. The main ones include the following:

• Iron doors are stronger and safer than wooden ones. The metal structure can resist burglary longer.
• They are more comfortable to use. Excellent sound insulation is combined with fire protection properties.
• The service life is significantly longer. Metal doors are less likely to deteriorate and break, and are more resistant to adverse factors.
• Modern Decoration Materials allow us to implement a variety of design solutions that meet the wide range of customer requirements. Today you can easily choose entrance doors that harmonize with any interior and style.

Material of manufacture and design

Entrance iron doors are manufactured on high-precision CNC machines. The materials used are high-strength and of stainless steel, including cold rolled alloy.

Structurally, between models different manufacturers there are few differences.

Any door consists of:

• Canvases.
• Frame.
• Heat and sound insulation.
• Interior and exterior finishing.
• Fittings, handles, eyes.
• Locks, latches.
• Hinge units, hinges.
• Sealant.

The door leaf - steel sheets - is welded on the outer and inner sides to the frame, which is made of angle, bent steel profile or pipes. The space between the sheets is filled with insulator - expanded polystyrene, mineral wool or wood. Locks and latches are embedded inside the box. Hinges and door handles, as well as decorative trims, are installed on the outside.

All-metal structures are used to protect premises with special requirements - bank vaults, cash registers, etc. and are called armored.

Features of designs of Russian manufacturers

Russian companies use solid steel sheets with a thickness of 2-4 mm for the production of canvas, while most imported analogues boasts 1.5 mm.

As a rule, two or three loops are used, but always with ball bearings. This ensures there is no drawdown over time. Some models are equipped with hidden hinges and anti-burglary pins. The hinges are manufactured using special technologies that provide increased loads on the hinge units.

The stiffening ribs and frames of metal structures are made from solid (usually bent) steel elements of increased thickness, which allows the door to maintain its shape long time without deformation of the canvas in case of mechanical shocks. The best type of sealant used is rubber.

The locks are located in special metal pockets that prevent quick access to the mechanisms. As locking mechanisms Russian manufacturers use two locks at once - cylindrical and level with four or more bolts, the thickness of which starts from 2 cm.

Keyholes often have multiple layers of protection.

Powder coating is often used as an external finish, which is highly resistant to mechanical stress and other adverse effects. Some Russian models have removable interior trim panels.

Steel door classes

Depending on the cost, iron entrance doors have several gradations.

Economy class includes products that provide a minimum level of protection at a fairly low cost. They are distinguished by a simplified design, materials of manufacture, finishing and fittings of low quality. At the same time, the design of Russian-made products can be very attractive.

Doors of this class from Russian manufacturers are manufactured in compliance with technology, due to which they have good heat and sound insulation. The middle class is the main product in the market. The combination of guaranteed high quality materials used and average quality fittings ensures popularity among the general public.

Premium class doors have a more elaborate design. Structural elements are made exclusively from high quality materials. They are characterized by an increased level of resistance due to the use of additional security elements that complicate hacking. Locks and fittings are used only of the highest quality from renowned manufacturers, and the finishing uses the most expensive materials, due to which the products wear out less.

There are four classes of entrance doors depending on their burglary resistance, which is largely determined by the quality of the lock.

According to GOST, these are the following:

• First grade. This includes locks with low tamper resistance.
• Second class. These are locks that have an average level of security characteristics, and strength characteristics that are lower than that. Opening time without a key is approximately five minutes.
• Third class. These locking devices are characterized by high security qualities with average strength of materials. Hacking is carried out in 10 minutes.
• The fourth class is distinguished by the highest burglary resistance rates - about 30 minutes. Locks are made from durable materials.

Metal doors are also classified by analogy with locks. In terms of burglary resistance, a door can:

• Regular. This is economy class. It is equipped with locks of 3-4 classes, as well as simple blocking devices.
• Reinforced. The locks are also 3-4 classes, but with many crossbars and blockers. They have reinforced hinges. This is the middle price segment.
• Protective. In addition to the most the best castles and locking means are able to resist squeezing or squeezing out the box.

Based on the type of decorative coating, steel entrance doors are divided into several groups:

• With transfer coating. Transfer printing technology is used - transferring an image from an intermediate medium. The pattern and texture often simply imitate more expensive types covering, but attractiveness is ensured. Suitable for doors installed in places protected from sun and moisture.
• Teflon coated. Usually the product is black. The material does not scratch or fade. Well suited for doors in contact with the street - cottages and summer houses.
• With auto enamel coating. Conventional spray painting is used - a balance between quality and visual appeal.

• Hammer coated. Powder coating with hammer paints makes it scratch and chip resistant. More often, the inner side has a transfer coating selected for the interior.

Metal doors can have standard and non-standard sizes. The second category includes products made to order. Based on the number of locks, metal doors are divided into single- and multi-locking.

According to the method of opening, metal structures are divided into right-handed and left-handed, opening only 90 or all 180 degrees.

Selection rules

The choice is based on cost, burglary resistance indicators, assessment of the quality of insulation and visual appeal. Practice shows that they buy more doors middle class, having acceptable characteristics and design at an adequate price. Experts pay attention to the following:

• Opening size. The standard product has dimensions of 2x0.8 m, so the opening is always measured before purchasing.
• To thickness sheet metal. The best samples have a thickness of 4 mm.
• On the thickness of the material, manufacturing method and width of the box. The box must be at least 7.5 cm wide - this is required by thermal insulation.
• On the quality and quantity of insulation and sealing.
• For the secrecy of locks, the presence of anti-burglary pins, protective linings on keyholes. The best Russian doors are equipped with a complex of such devices.
• On the quality of fittings, handles, peephole (viewing angle is important) and finishing.

The best Russian manufacturers

Some of the most popular Russian doors are models from the following manufacturers:

• Guardian. They are characterized by increased strength and resistance to burglary. The design uses multi-layer well protection, environmentally friendly insulation and high-quality powder coating.

Consumers appreciate Guardian for the ability to select designs, fittings, sizes, and custom-made locks.

• Elbor. These entrance doors are distinguished by a presentable appearance without unnecessary frills. The advantages of the products include reliability, replaceability decorative panels, multi-point locking systems, the possibility of installing an additional armor package and mounting on any side.

In the video you can familiarize yourself with the rules for choosing metal doors:

• Condor. The products combine relatively low cost with high quality assembly and manufacturing materials. Exclusively mineral wool is used as a heat insulator.
• Thorex. They are distinguished by high quality workmanship and discreet design. The manufacturer pays great attention to the quality of materials and workmanship. The products are characterized by a high level of sound and heat insulation due to the use of expanded polystyrene. For the same reason (expanded polystyrene is not afraid of moisture), they are more suitable than others for installation outside the city. Suitable for use as an entrance door from the street.
• Outpost. The products of this company are one of the most popular on the domestic market. The advantages of doors from this manufacturer include reliability, durability and strength, as well as the availability hidden loops. The latter circumstance has a positive effect on their burglary resistance. Forpost products have a modern design and fit into any interior.

Technical doors are affordable, which is important when they are used to equip premises in enterprises, basements, workshops or rooms with equipment. They are often installed at exits that are used only during evacuation or in control rooms and elevator rooms. The low cost of the design does not mean low quality, because the production of technical doors is carried out using modern equipment and technologies that make it possible to create reliable products from cold-rolled steel and budget insulating materials.

Manufacturing of metal structures for technical doors

For the large-scale production of high-quality technical doors, factories use modern equipment with precise cutting and bending of steel sheets, which is radically different from their homemade garage counterparts. The process begins with metal cutting, where a laser machine with a moving head moves along a given template and cuts out precise elements. This is how blanks for the box and canvas profile are created. Holes for the hinges are immediately cut on the machine. This technology allows us to produce parts with smooth edges and the required size without errors.

Next, the blanks are placed on a press, where there is a matrix with a right angle, into which the steel is pressed by the incoming mating part. Using this technology, box racks are made and the side of the canvas is folded. Several bends can be made on each product, which gives a stepped profile shape and subsequently the ability to place several sealant contours on it.

To decorate the appearance of the canvas, sheets of steel are stamped with extrusion of a pattern in the form rectangular tiles or arches. Further, the production of technical metal doors is carried out using resistance welding or semi-automatic welding, where two prepared sheets with curved sides are placed next to each other and connected with short seams with an interval of 200-300 mm. This forms a rigid structure that can maintain the correct geometry and withstand loads during operation.

Insulation is first placed in the cavity. If this is a structure for ordinary purposes, then corrugated cardboard is used, and for fire doors, mineral wool is used, which is completely non-flammable and does not emit harmful fumes. The box contains loops of hidden or open type. There can be from three to four. It is possible to manufacture doors with two equivalent leaves for wide openings or with a main and auxiliary one, opening as needed.

The leaf is equipped with anti-removal pins, welded at the end of the sash from the hinge side and extending into the frame. In the closed position, when cutting off the open hinges, the doors will not fall out. To strengthen the area around the locks, armor plates or complex protection can be used.

In order for technical doors to maintain an acceptable appearance for a long time, they are coated with a special composition:

1. The canvas is disconnected from the box and suspended on a rope conveyor.
2. Products move inside spray booth and heat up to a temperature of 180 degrees.
3. Powder with a coloring pigment is supplied from the nozzles, which adheres to the heated iron.
4. When melted, the granular product forms a continuous thick layer on the surface of the door.
5. The structure cools down and moves out.

The powder coating used in the production of technical doors contributes to their long-term protection against corrosion even at outdoor installation or in areas with high humidity. This painting withstands ultraviolet radiation well, and also has a dense structure, which protects the doors from scratches and chips.

After painting, the seal contours are glued to the product. A hollow rubber band with a sticky base is placed around the perimeter on the ledges of the frame and sash. This seals the opening not only from dust and debris, but also from cold air or unpleasant odors. Fire-resistant models use graphic material that foams when heated and protects the inside from smoke penetration.

Inserting locks on technical doors

On final stage In production, locks are inserted. Due to their technical purpose, valuable materials are rarely stored behind such canvases, so it is sufficient locking devices 2nd class of burglary resistance. Most often, products are equipped with cylindrical locks with four bolts with a diameter of 13-16 mm. Holes for the handle, hole and peephole are drilled on the sash.

A five-channel locking system is also used in the manufacture of technical metal doors, where guides with crossbars are first inserted inside. At the end of the insertion rods there are loops for the hooks from the lock to fit in to unite the entire mechanism. This provides a stronger fixation of the door in the opening during attempts to break in by force.

The online store "Reliable Doors" contains a large assortment technical doors. There are models with one, one and a half and two doors, as well as fire-resistant leaves with a graphic seal and a fire resistance certificate.

Products manufactured by the plant steel doors, will differ favorably from self-made structures. A high-quality entrance door must combine reliability and respectable appearance, and also have a number of important performance qualities: burglary resistance, noise insulation, thermal insulation, structural strength and resistance to various external influences.

The market offers a huge selection of steel doors, both foreign and Russian-made. A big advantage of domestic manufacturers is the production of custom-made doors according to individual parameters, a huge selection of finishes and a relatively low price.

Equipment for the production of metal doors

Basically, the production of iron doors is carried out in two ways: on fully automated lines of large factories, where one door takes up to 10 minutes, and semi-automatic lines using manual labor.

In the first case, the main advantage is the low defect rate, due to the lack human factor, and production volumes: such an enterprise can produce up to 500 doors per day!

The disadvantages include the high cost of equipment and its maintenance and the size of the required production area.

On semi-automatic lines, things go slower - the same day is spent on producing only 20 metal doors, or even less. Here the need for qualified personnel increases, but despite this, the percentage of defects significantly exceeds the rate of automated production. The advantages include quite a reasonable amount of start-up capital for the purchase of equipment and the small space required for production.

Cutting patterns and blanks from steel sheets

The production of a metal door begins with careful measurements and selection of the metal itself. After arriving at the plant, the steel sheets are carefully checked for deformation and corrosion and are stored separately in specially equipped rooms. Optimal thickness steel sheet 2-3mm. At the customer's request, the door is also made from 5 mm steel.

From the selected sheet, a blank for the future door is cut out with all the mounting holes for locks and hinges cut out. Accuracy is ensured by a special computer program.

From the same sheet, parts are cut out into blanks for the door frame using a metal stamp. Besides steel frame The door also uses stiffening ribs, which ensure the strength of the entire structure. The profiles are located vertically and horizontally inside, which allows for maximum strengthening of the door leaf.

The door can also be made not from a single sheet, but by welding several steel sheets. The price of such a product will be significantly lower, as will its strength indicators.

In this case, seamless welding is used to avoid bursting seams during installation and further operation.

Unscrupulous Chinese manufacturers have established the production and sale of doors made of reinforced foil sheets. Such products can be easily and quickly hacked with any household tool, from a knife to a hammer, and their installation is only advisable in empty objects where only minimal protection is needed, for example, from precipitation or wild animals.

The remaining blanks are given the necessary shape for the manufacture of a door profile on a sheet bending machine. The shape of the bends is precisely maintained according to the technical specifications.

Hinges are welded to the door posts and door frame using electric arc welding. Compliance with exact dimensions during installation is ensured by clamps that hold the hinges at the required distance. This device is called the door frame assembly jig.

Welding parts into a single whole

Meanwhile, assembly or, in other words, scalding occurs. Parts of the door frame are placed on the table and the door leaf with corner reinforcements is placed on top. After the structure is secured with clamps, spot welding begins. In places where the welding machine comes into contact with the steel sheet, rivets of molten metal appear, indicating that the structure is securely fastened.

In this case, the correct geometry of the door frame is strictly observed: all angles are 90°.

Before passing technical control, where all gaps, welds and overall quality assembly, grinding and cleaning of all joints takes place, all burrs and so-called “scale” are removed. After which the future door is washed with a phosphate solution, which not only removes dirt and oil, but also covers it with a special film that protects it from rust.

Next in line is the painting stage. By using special device a special coating is applied to the door powder paint, which is resistant to chipping and, of course, corrosion and is sent to the oven for 30 minutes at 210°.

Final stage of production

In parallel, in another part of the workshop they are preparing interior decoration: an overlay is cut out from MDF boards with drawing on a milling machine. At the request of the customer, this overlay is covered with one of the selected coverings: artificial or natural leather, laminate, plastic or decorative film. Finishing options can be chosen to suit every taste.

In the assembly shop, the assembly process begins with the fitting of locks, which are additionally protected by armor plates. The choice of locks is no less important than the choice of the door manufacturer and the material from which it is made. The best option is considered to be a combination of two locks: level and cylinder. In this case, you can be sure of high level burglary resistance of the door. The door is also equipped with a peephole and handles.

Voids door leaf filled with mineral wool, which will improve heat and sound insulation performance. In budget options, the use of foam and other inexpensive materials is allowed. In places where the door leaf adheres, to protect it from wind and dust, a seal is placed, which also increases the thermal insulation properties of the door.

At the ends of the door, flashings are installed, which are designed to cover the vestibule of the structure.

They also eliminate existing cracks and open spaces, bringing the door space together into a cohesive whole.

Installation and service

Despite the fact that the installation stage is the final one, it is no less important than all the others. It is better to entrust this work to professionals - the door manufacturers themselves. Then you can be sure that the installation will take place in compliance with all installation rules and regulations and the new door will serve faithfully for many years.

Nowadays, more and more often, representatives of Russian production and foreign factories do not stop at this stage, but offer additional service. If the key is lost, the lock is broken or door knob, there is no need to go shopping, look for a replacement and a technician to do the work on your own. The door manufacturer will take care of everything and take care of this too.

In the current conditions, anyone can easily find a metal door on the market in accordance with their preferences and tastes. Numerous companies offer products of the most different designs. However, quite often there is a need to do self-production such a door.

Making metal doors with your own hands can be dictated by a number of reasons:

• unique design or geometric requirements;
• desire to use the original design solution;
• the use of specific materials;
• the desire to obtain a high-quality product (as they say, “if you want to do something beautifully, do it yourself”);
• desire to save money.

Of course, making a metal door with your own hands cannot be called an easy task, but with some skill, the necessary knowledge and tools, you can cope with this task in a fairly short time. One of the main conditions is careful adherence to the sequence of operations.

Necessary materials, equipment and tools

To make metal doors you will need following materials, equipment and tools:

• metal corner;
• steel sheet with a thickness of 1.5 mm;
• door hinges (their number depends on the strength of the hinges themselves and the weight of the door);
• fittings: lock, door handle, etc.;
• cladding material (plywood, board or veneer - depending on your preferences and availability of materials);
• construction foam;
• drill;
• anchor bolts;
• grinder with a disc designed for cutting metal;
• welding table or trestles for assembling the product.

But manufacturing and installing metal doors is a creative endeavor. Therefore, the above list can be considered approximate to some extent: a lot depends on the type and design of the door you decide to choose. For an entrance door, for example, it is worth taking a steel sheet of greater thickness or creating a “sandwich” type structure, which consists of two sheets of steel with foam plastic or other insulation between them.

Making a door frame

Work must begin with accurate measurements of the opening. Most often, a standard opening has a width of 800-900 mm and a height of 2000 mm. In order to avoid errors in measurements, it is necessary to “get” to the end of the wall (concrete or brick) by knocking down a layer of paint and plaster in a short area and making a cutout using a hammer and chisel in the vertical casing, if any.

This operation should be performed on all four sides from the outside and inside of the opening. When you have decided on the true outlines of the opening, you can take measurements.
After the dimensions of the opening are precisely determined, we begin making metal doors with our own hands.

Dimensions metal box the doors must be such that there is a gap of 20 mm wide between the ends of the walls delimiting the opening and the frame. It will allow you to adjust the position of the door during installation if the opening is skewed. Upon completion installation work This gap is sealed with construction foam.

First of all, you need to cut a corner to the size of the box (with a shelf length, for example, 50x25 mm) of the required length and lay it out on some plane (preferably on a welding table) in the shape of a rectangle. Instead of a welding table, you can use sawhorses calibrated for flatness. To make sure that all corners of the box are equal to 90 degrees, you need to measure the lengths of the diagonals. They must be equal. Then the corners are welded.

Manufacturing of door leaf

The manufacture of a metal door begins with determining the dimensions of the frame. It must be sized so that between it and the box there is a gap of 20 mm in height and 15 mm in width (see below for the distribution of gaps around the perimeter). Then a corner of the required length is cut off (a 40x25 corner is suitable) and laid out on the table in the shape of a rectangle, after which the frame is welded.

Immediately after this, you should make a cutout in the profile with an angle grinder to install the lock. In order to facilitate the work on door trim, wooden slats of the required length are driven into the frame. Next, a loop profile is welded to the hinges and the box. This is done to facilitate welding work.

It is necessary to very carefully measure the distance between the hinges on the frame and the door frame to achieve a complete match. Otherwise, problems may arise when hanging the door. Then you need to lay the door frame inside the frame and ensure that all sides are parallel.

The next step in the technology for manufacturing metal doors involves preparing the door leaf. The steel sheet is cut in such a way that the sheet covers the opening by 1 cm, and on the side of the lock - by 1.5 cm. After cutting, scale remains on the edge of the sheet, which must be removed.

The prepared sheet is laid in such a way that the top and bottom edges of the box protrude by 10 mm. From the side of the lock the box should protrude by 5 mm, and from the side of the awnings by 15 mm. In several places we carefully grab the sheet to the box.

Then we turn the box over so that the sheet is at the bottom. Inside the box is a door frame.

We set the gaps between the frame and the box:

• from below (from the threshold side) – 10 mm;
• top – 10 mm;
• from the lock side – 8 mm;
• from the canopy side – 7 mm.

To fix the gaps, you can use improvised means: strips of metal of different thicknesses, discs from an angle grinder, etc.

Now you can weld the frame to the sheet

Need to cook in small areas: the seam should be no longer than 40 mm, the distance between the beginnings is 200 mm. Welding should begin from the middle to the edges of the product in reverse steps with different sides. The product must be allowed to cool periodically.

Installation of door hinges

Before proceeding with the installation of hinges (canopies), it is necessary to lift the product above the plane of the welding table. To do this, place pieces or profiles under the box. Metal door diagram

To make loops, a steel rod with a diameter of 20 mm is used. To facilitate the operation of the hinges, a steel ball from a bearing is placed in each of them. The hinges are assembled and fixed to the structure so that the upper and lower hinges are coaxial. Then the hinges are welded to the frame and door leaf.

The upper part of the loop is welded to the sheet, and the lower part to the box.
After you have welded the hinges, cut off the tacks that secured the sheet to the box.

The production of metal entrance doors is completed by cleaning the welds and painting. Staining should be done regardless of what finishing you plan to do next. A coat of paint will prevent rust from occurring, protecting the metal from corrosion.

Lock installation

To install the lock in the flange of the door frame corner, make a cutout of such a size that the lock fits into it without a gap. After installing the lock, you need to mark all the holes: mounting, key, handle, etc. According to the completed markings, it is necessary to drill holes of the required diameter.

In addition, you need to make holes around the entire perimeter of the door for screws with a diameter of 4 mm, with which boards will be screwed to the door from the inside (one of them should have a cutout for a lock). For fastening, you can use screws 35-40 mm long.

All cutouts for the latch and various latches in the box are made only when the box is installed and the door is hung. At the stage of installing the lock, a door peephole is also made.

Finishing works

The production of non-standard metal doors implies an original finish. The door can be sheathed with wooden planks or canvas, as well as upholstered with soft material or covered with a film with a pattern and “wood-like” texture. A less labor-intensive option is to simply paint the door. At the same time, decorative elements can be welded onto the canvas. forged elements, which will transform the appearance of the product.

As you can see, anyone who is at least a little familiar with repair work and knows how to make a metal door can make a metal door. While admiring the result of your labor, do not forget to note that your decision to do this work yourself allowed you to save a significant amount.

According to the described algorithm, almost all doors are made of metal. Exceptions occur only in the production of special products, for example, when fire-resistant metal doors are being manufactured.

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• Introduction
• 1.2 Inverter arc power supplies
• 1.3 Selecting electrodes and welding mode
• 2.1 Door classification
• 2.2 Procedure for assembling a metal door
• 3. Occupational safety
• Conclusion
• Bibliography
• Introduction
• In this course work, I will try to explain in detail the procedure for assembling and installing a metal door using manual arc welding.

Welding is used to connect various metals, their alloys, some ceramic materials, plastics, glass and dissimilar materials. The main application is welding of metals and their alloys in the construction of new structures, repair of various products, machines and mechanisms, and the creation of two-layer materials. Metals of any thickness can be welded. The strength of the welded joint in most cases is not inferior to the strength of the whole metal.

The connection during welding is achieved due to the emergence of atomic-molecular bonds between the elementary particles of the connected bodies. The bringing together of atoms is hampered by the roughness of the surfaces in the places where the parts are to be joined, and the presence of contaminants in the form of oxides on them.

Depending on the methods used to eliminate the reasons that hinder the achievement strong connection, All existing varieties welding (and there are about 70 of them) can be classified into three main groups - pressure welding (solid state welding), fusion welding (liquid state welding) and fusion and pressure welding (liquid-solid state welding).

In fusion welding, the connection of parts is achieved by local melting of the metal of the welded elements - the base metal - along the edges at the point of contact or the base and additional metals and wetting the solid metal with liquid. The molten base or base and additional metals spontaneously (spontaneously) merge without the application of external force, forming a common so-called weld pool. As the heat source is removed, solidification occurs—crystallization of the metal weld pool and the formation of a seam connecting the parts into one. The weld metal in all types of fusion welding has a cast structure.

Powerful heating sources are used to melt the metal. Depending on the nature of the heat source, electric and chemical fusion welding are distinguished: with electric welding, the initial source of heat is electric current; with chemical welding, the exothermic reaction of gas combustion (gas welding) or powder is used as a heat source. combustible mixture(thermite welding).

• Goal of the work:
• Study the features of assembly and installation of a metal door made of sheet and corner steel St3.
• Tasks: learn to choose the right sizes, necessary materials, amperage and welding methods for assembling and installing a metal door.
• Relevance. Doors of this type are widely in demand in industrial, warehouses, in basements, garages, technical rooms, as well as apartment buildings, as the entrance door to the apartment and entrance.
• 1. General information about the steel used. selection of arc power source, electrodes and welding mode
• 1.1 General information about the steel used
• Steel is an alloy of iron with carbon and/or other elements. Steel contains no more than 2.14% carbon. In this case, we use steel grade St3, which means carbon structural steel of ordinary quality (see Table 1).
• Table 1

Substitute
Classification	Structural carbon steel of ordinary quality
Application:	load-bearing and non-load-bearing elements of welded and non-welded structures and parts operating at positive temperatures. Shaped and sheet metal up to 10 mm thick for load-bearing elements of welded structures operating under variable loads in the range from -40 to +425 °C. Rolled products from 10 to 25 mm - for load-bearing elements of welded structures operating at temperatures from -40 to +425°C, subject to delivery with guaranteed weldability.
Chemical composition in % of steel grade 3 (St3sp)

1.2 Inverter arc power supplies

The choice of power source for the welding inverter in such cases is carried out from autonomous generators various types. Incorrect choice using an autonomous generator as an external power source for the welding inverter can lead to its rapid failure. When choosing a generator, it is not enough to limit yourself to just selecting power. There are other characteristics of an external autonomous generator that are not compatible with the operating characteristics of the inverter.

Powering the welding inverter from an external city or power network does not cause incompatibilities that affect the operation of the welding inverter. All welding units available on store shelves are adapted specifically for mains power. The input rectifier unit at the input of the welding converter is designed to operate with a frequency of 50 Hz and a voltage of 220 or 380 volts, i.e. with a regular or power network.

The discrepancy in the operation of the generator and inverter arises due to the difference in the nature of the load. When the inverter operates, they carry a capacitive component. Generators, in turn, are designed for active-inductive consumers, and when the load current increases, they compensate for the voltage drop. In this case, when the current increases due to the capacitive component of the load, the inverter has its own voltage increase, and the current feedback from the generator, compensating the voltage from the load, causes an even greater increase in voltage in the inverter module. An overvoltage that occurs with increasing intensity can lead to failure of the device or a decrease in the operating resources of the electronic circuit.

A similar situation does not arise when connecting welding rectifiers and transformers made according to the autonomous generator power circuits. Their active-inductive load is fully compatible with the operating characteristics of generators of all types of excitation. For inverters, it is possible to use generators with increased power. With a power reserve of two times, it is possible to avoid an increase in voltage at the generator when the inverter is operating. The second option is to use special generators designed for active-capacitive loads. This can provide a reduction in the no-load voltage of the generator and an increase in the current frequency to 52Hz.

If the generator power reserve is insufficient, then it is better to use an external network to connect the welding inverter for operation.

In this work I used Welding machine Brima ARC 250 inverter type is designed for manual arc welding and stick electrode surfacing on DC steel products in industrial and domestic conditions. It features stable, reliable and efficient operation, portability and low noise during welding process. Features of the ARC 250 device are high efficiency, low level energy consumption, mobility, excellent dynamic properties, arc stability, low open circuit voltage, self-regulation of arc power, ability to meet various welding requirements.

Adjusting the arc force (short circuit current) allows you to optimally select the depth of metal penetration and avoid increased metal spattering and (or) electrode sticking.

1.3 Selecting electrodes and welding mode

When fusion arc welding, consumable electrodes are used, made of cold-drawn calibrated or hot-rolled wire with a diameter of 0.3-12 mm, or flux-cored wire. Electrode strips and plates are also used as electrodes. Electrodes are classified according to material, purpose for welding certain steels, thickness of the coating applied to the rod, type of coating, nature of the slag formed during melting, technical properties weld metal, etc. A certain composition is applied to all electrodes - a coating.

The general purpose of electrode coatings is to ensure stability of the welding arc and obtain weld metal with predetermined properties. The most important properties are ductility, strength, impact strength, and corrosion resistance. The coating performs many important functions.

Firstly, it is gas protection of the welding zone and molten metal, which is formed during the combustion of gas-forming substances. It protects the molten metal from exposure to oxygen and nitrogen. Such substances are introduced into the coating in the form of wood flour, cellulose, and cotton fabric.

Secondly, deoxidation of the weld pool metal by elements that have a greater affinity for oxygen than iron. These elements include manganese, titanium, molybdenum, chromium, silicon, aluminum, and graphite. Deoxidizers are included in the coating not in pure form, but in the form of ferroalloys.

Thirdly, slag protection. The slag coating reduces the rate of cooling and hardening of the weld metal, thereby facilitating the release of gas and non-metallic inclusions. The slag-forming components of coatings are titanium and manganese ores, kaolin, marble, quartz sand, dolomite, feldspar, etc.

Fourthly, alloying the weld metal to give it special properties (increasing mechanical properties, wear resistance, heat resistance, corrosion resistance). Chromium, nickel, molybdenum, tungsten, manganese, and titanium are used as alloying components.

In addition, to increase welding productivity, iron powder is introduced into the electrode coatings. This powder facilitates re-ignition of the arc, reduces the cooling rate of the deposited metal, which has a beneficial effect on welding at low temperatures. The powder content can reach up to 60% of the coating mass. To secure the coating on the electrode rod, binders are used, such as liquid glass. To give the coating better plastic properties, forming additives are introduced into it, such as bentonite, kaolin, dextrin, mica, etc.

Depending on the materials being welded, all electrodes are divided into the following groups: L - for welding alloyed structural steels with a tensile strength of over 600 MPa - five types (E70, E85, E100, E125, E150); U - for welding carbon and low-carbon structural steels; B - for welding high-alloy steels with special properties; T - for welding alloyed heat-resistant steels - 9 types; N - for surfacing surface layers with special properties - 44 types. The guaranteed tensile strength of the weld metal is indicated by numbers in the electrode brand. For example, the name of the electrode, designated E42, indicates that it is intended for arc welding; the minimum tensile strength of the weld metal is 42 kgf/mm 2 .

The choice of the diameter of the electrode for welding is carried out depending on the thickness of the metal being welded, its grade and chemical composition, the shape of the edges, the welding position, and the type of connection. The main features of different electrode diameters include:

1. Welding electrodes 1 mm - designed to work with metal whose thickness is 1-1.5 mm, with a current of 20-25A;

2. Welding electrodes 1.6 mm - in accordance with GOST 9466-75 for low-carbon and alloy steel, are available in two sizes 200 or 250 mm, used for working with metals whose thickness is from 1 to 2 mm with a current strength of 25-50A;

3. Welding electrodes 2 mm - according to GOST 9466-75 for low-carbon and alloy steel, they are made 250 mm long, a length of 300 mm is also allowed, the thickness of the metals being welded is from 1 to 2 mm, the current strength is 50-70A;

4. Welding electrodes 2.5 mm - according to GOST 9466-75 for low-carbon and alloy steel are produced in lengths of 250-300 mm, a length of 350 mm is also allowed, the thickness of the metals being welded is from 1 to 3 mm, the current strength is 70-100A;

5. Welding electrodes 3 mm - the most widely used electrode diameter, in accordance with GOST 9466-75 for low-carbon and alloy steel, are available in three sizes 300, 350 and 450 mm, designed to work with metals whose thickness is from 2 to 5 mm with current strength 70-140A;

6. Welding electrodes 4 mm - a widely used diameter suitable for work on both professional and household equipment. Produced in accordance with GOST9466-75 in two sizes 350 and 450 mm for any types of steel, for metals whose thickness is from 2 to 10 mm with a current strength of 100-220A;

7. Welding electrodes 5 mm - electrodes of this diameter require sufficiently powerful welding equipment. In accordance with GOST 9466-75, they are manufactured with a length of 450 mm for low-carbon and alloy steel, and a length of 350 mm is also allowed for high-alloy steel. Designed to work with metals whose thickness is from 4 to 15 mm with a current of 150-280A;

8. Welding electrodes 6 mm - designed for use on professional equipment. According to GOST9466-75, it is produced in a length of 450 mm for low-carbon and alloy steel, and for high-alloy steel, a length of 350 mm is also allowed. Designed to work with metals whose thickness is from 4 to 15 mm with a current strength of 230-370A;

9. Welding electrodes 8-12 mm - for work on high-performance industrial equipment. In accordance with GOST 9466-75, it is produced in a length of 450 mm for low-carbon and alloy steel, and for high-alloy steel, a length of 350 mm is also allowed. Designed to work with metals whose thickness is over 8 mm with a current strength of 450A;

It should be noted that for a certain electrode diameter, the current range for each brand of electrode is different. For example, with an electrode diameter of 3 mm for UONI 13/55 the current is 70-100A, and for MP-3 the current is 80-140A.

If manual arc welding is carried out, then it is performed in 2-3 layers, since multilayer welding provides deep penetration of the root and increases the density of the welded joint. This method is used with and without rotation of the welded joints. To avoid metal burn-through, it is recommended to weld the first layer with electrodes with a diameter of 4 mm at a welding current of 120-140 A. The layers should be welded in one direction with a gradual rotation of the welded section. If a non-rotating joint is welded, then welding is carried out when connecting the sections into one string and the final installation of the pipeline. The order of applying welds is as follows: the first layers are welded from bottom to top; subsequent seams - from top to bottom. Locks, or closing areas in adjacent layers of the seam, should be spaced from each other at a distance of approximately 60-100 mm; in the ceiling part of the seam it is convenient to finish welding at a distance of 50-70 mm from the bottom point of the pipe. If it is impossible to weld non-rotating joints, then a combined method is used. With this method, the joint is welded with the insert, while the lower part of the seam is welded from the inside; the upper part of the seam is welded with outside. The type of electrodes used is the same as when welding rotary joints. If main pipelines are being laid, then manual welding is carried out only when applying the first layer of seam.

Welding mode refers to the main indicators that determine the welding process, which are established on the basis of initial data and must be performed to obtain a welded joint of the required quality, size and shape established by the project. These indicators for manual arc welding include: brand of electrode, its diameter, strength and type of welding current, polarity with direct current, number of layers in the seam. For a multilayer weld - the diameter of the electrode and the current strength for the first and subsequent layers, as well as other characteristics. To determine the welding mode, initial data are used, for example, the grade and thickness of the base metal, the length and shape of the welds, design requirements for the quality of the welds (electrode type), and the position of the seams in space.

Depending on the brand of metal being welded and its thickness, the type and brand of electrodes are selected. The diameter of the electrode is selected depending on the welding position and the thickness of the metal. In the lower welding position, the diameter of the electrode can be determined based on the relationship between the diameter of the electrode and the thickness of the metal being welded

The cross-sectional area of ​​multi-layer seams is usually given in the Unified Standards and Prices for Welding Work, from which the number of layers (passes) of a multi-layer seam can be easily determined.

Welding mode. In this work we use the electrode brand UONI 13/55, the electrode diameter is 3 mm. The position of the seam in space is vertical, bottom and ceiling. Current 75 - 100 A (depending on the position of the seam in space)

When welding in a vertical position, the current decreases by 10-20%, when welding horizontal seams - by 15-20% and when welding ceiling seams - by 20-25%. When welding in the lower position, the current strength will be equal to 100A, in the vertical position 80 - 100A, and when welding in the ceiling position, the current strength will be equal to 75 -80A.

The welding speed (arc movement) largely depends on the qualifications of the welder and his ability to conduct the welding process with breaks only for changing the electrode. In addition, the welding speed is influenced by the deposition rate of the electrodes used and the strength of the welding current. The higher the deposition rate and the higher the current, the faster the arc moves and, therefore, the welding speed increases. It should be borne in mind that an arbitrary increase in current may cause overheating of the electrode.

steel electrode welding door

2. Classification of doors. metal entrance door manufacturing technology

2.1 Door classification

I. Based on materials:

Wooden,

Aluminum,

Steel,

Plastic,

Combined.

II. By opening method

1. Swing

They can open in one direction or both. Both internal and external doors can be hinged.

2. Sliding

Sliding doors widely used for wardrobes. Sliding doors go into a cavity inside the wall or move parallel to it.

3. Rocking

They swing open in both directions, like in the subway, and pets love them. But they are almost never found on sale, only in specialized stores.

III. By purpose they are distinguished:

1. Doors for residential buildings

2. Doors for public buildings

3. Special doors (shockproof, bulletproof, burglar-proof)

Door designs are different and depend on the requirements placed on them. Both in Russia and abroad, they produce doors that open inside the room.

2.2 Procedure for assembling a metal door

1. First of all, we weld the door threshold onto the tack.

2. Marking and cutting sheet steel.

2.1. We will need 2 leaves for a large and a small door. We draw marking lines on sheet steel using a metric tape measure and chalk. (Fig. 1. a, b).

2.2. Using an angle grinder, we cut out the 1st blade from sheet steel 3 mm thick, 900 mm wide and 1980 mm long and the 2nd blade 1980 mm long and 490 mm wide (Fig. 2.).

a b

Fig.1.

Fig.2.

2.3. Marking and cutting angle steel. They will serve as stiffening ribs for the product. We cut out the corner steel, which will be positioned vertically, for the 1st large and for the 2nd door leaf of the same length of 1980mm. Next, the mode is horizontal corners, short for a small door 485mm long and long 870mm: (Fig. 3.).

Fig.3.

3 Assembling the door on tacks using 3mm W electrodes, grade UONI-13/45

1.1. We weld the stops to the threshold, at a distance of 10 mm from the butt (Fig. 4. a, b)

a b

Fig.4.

We grab the stiffeners. First, we grab the longitudinal ribs (Fig. 5. a.), then the transverse ones (Fig. 5. b, c.) The distance from the channel wall should not exceed (5 mm). Tacks should be 35-50 mm long, at a distance of 150-200 mm. We do the same with the second, small door leaf.

a B C

Fig.5.

1.2. We weld the embedded plates onto which the hinges will be welded. Their length should slightly exceed the length of the hinge cup. In order for everything to be smooth on the channel, we weld 2 plates, one on top of the other, they should deviate from the door leaf by about 5-6 mm, and on the door leaf we weld 1 plate, the distance from the edge is 2-3 mm. We process the plates: (Fig. 5.).

a b

Fig.6.

1.3. We weld the hinges to the finished embedded plates: (Fig. 7.).

Fig.7.

1.4. We insert the lock. We cut through the keyhole (Fig. 8, a). In order to fix it, we use angle steel (Fig. 8, b) and fasten the lock with self-cuts: (Fig. 8, c).

a B C

Fig.8.

1.5. We clean the seams from slag and splashes. We perform a visual inspection of welds. If defects are detected, we cut out the required section of the weld and weld it again.

Defects and their elimination. Defects in welded joints must be eliminated in the following ways: detected breaks in seams and craters are welded; seams with other defects exceeding the permissible ones are removed to the length of the defective area plus 15 mm on each side and welded again; undercuts of the base metal that exceed the permissible ones are cleaned and welded, followed by cleaning, ensuring a smooth transition from the deposited metal to the base metal.

Residual deformations of structures that arise after welding and exceed values ​​must be corrected. Correction must be carried out using thermal, mechanical or thermomechanical methods.

ITK on the topic: “Technological process of manufacturing an entrance metal door”

table 2

	Technological map of welding works
	Name	Quantity
	Equipment: rectifier	VDM 1001, RB-302
	Tool:	- Metal ruler; - Square; - angle grinder - Metal brush; - External control panels; - Slag separator; Electrode holder.
	Materials:	Electrodes brand UONI-13/45
			Total wall thickness	Current strength, A	Electrode diameter in mm	Seam length, mm	Number of points	Qualification category
	Installing the door threshold.
	Make markings and cut out 2 door leaves and stiffeners according to required sizes doors.
	We assemble the structure. We install stops. We weld the door leaf on tacks and fix it. To do this, we install supports under the canvas on which the canvas will stand.
	Attach the stiffening ribs to the door leaf. Electrode Ш 3 mm UONI-13/45. The length of the tacks is 35-50 mm.
	We weld the embedded plates onto which the hinges will be welded. We process the plates.
	We weld the hinges to the finished overhead plates.
	Let's start installing the lock. Keyhole mode. In order to secure it, we use angle steel and fasten the lock with self-tapping screws
	Cleaning seams from slag and splashes
		Execution order
	Perform a visual inspection of the welds.	1. Detection of external defects; 2. Removal of defective areas; 3. Correction of defects.

3. Occupational safety

When arc welding and cutting, the welder is exposed to factors such as harmful gases, fumes and irradiation from the welding arc. There is also a danger of electric shock. In addition, during operation, volatile compounds arise in the form of dust. It contains substances harmful to human health such as oxides of manganese, silicon, iron, chromium, and fluorine. The most harmful are chromium and manganese. When welding, the air is polluted with oxides of nitrogen, carbon, and hydrogen fluoride. Inhaling such polluted air is fraught with various health problems for a person. They are expressed by headaches, dizziness, nausea, vomiting and general weakness. In addition, toxic substances can be deposited in the tissues of the human body and cause various diseases. Working with coated electrodes causes the most air pollution; less harmful emissions during automatic welding. The effect of all these harmful factors can be significantly weakened or neutralized if safety measures are applied in each specific case.

For creating favorable conditions work that meets the physiological needs of the human body, sanitary standards establish optimal and permissible meteorological conditions in the working area of ​​the premises.

The microclimate in work areas is regulated in accordance with the sanitary rules and standards set out in “SanPiN 2.2.4.548-96. Hygienic requirements for the microclimate of industrial premises."

Production premises - closed spaces in specially designed buildings and structures in which work is carried out constantly or periodically work activity of people.

The workplace in which the microclimate is normalized is the area of ​​the room (or the entire room) in which labor activity is carried out during a work shift or part of it.

The work area is limited to a height of 2 meters above the level of the floor or platform where the workplaces are located.

Calculation of sanitary and hygienic premises is carried out according to SNiP 2.09.04-87. For calculation household premises information is required about the group of production processes according to sanitary characteristics.

Organization of the workplace. Depending on the nature of the work, welding can be carried out while staying in one place or periodically moving around the work site. That's why workplace The welder can be either mobile or permanent. Regardless of this, there is a strictly defined set of necessary devices and tools. Among them are: power supply, welding transformer, welding leads, electrode holder, face shield, canvas protective clothing, fencing shields, fire extinguishing equipment, necessary tools, asbestos sheet. If welding work is carried out in a cabin, then it is better to paint the walls of the cabin in a light gray color.

This type of coloring promotes better absorption ultraviolet rays. In addition, the cabin must have good lighting and ventilation. According to fire safety requirements, floors must be made of brick, concrete or cement. The dimensions of the cabin are 2 x 2.5 m. Its walls are made of thin metal, plywood, and tarpaulin. Both plywood and tarpaulin are impregnated with a fire-resistant compound. The welder's work table should not exceed a height of 0.6-0.7 m. The material of the table top is thick sheet steel. Fiber masks and shields protect the welder's eyes and face from harmful radiation. The inside of the body of shields and masks should have a matte, smooth black surface. Dark green filters (type C) also provide radiation protection.

If welding work is performed with coated electrodes, then it is better to choose the following filters: at a current of 100 A - filter C 5, 200 A - C 6, 300 A - C 7, 400 A - C 8, 500-600 A - C 9. If welding is carried out in carbon dioxide at a current of 50-100 A, then use a light filter C 1, 100-150 A -- C 2, 150-250 A -- C 3, 250-300 A -- C 4, 300 -400 A -- C 5. Electrical holders are needed to secure the electrode and supply current to it during manual arc welding. There are electric holders of passage, screw, spring, lever and other types. Electric holders allow you to fix the electrode in one of three positions: at an angle of 0, 45, 90° relative to the longitudinal axis of the handle.

Conclusion

In this work, we familiarized ourselves with one of the methods technical process assembly and welding of a metal door.

We got acquainted with the features of welding, defects and their elimination. We learned what the procedure for assembling a metal door should be, learned welding methods and how to choose the right electrodes and welding mode to improve efficiency.

Bibliography

1. Adaskin A.M., Materials science (metalworking): textbook. Guide for beginners prof. Education / A.M. Adaskin, V.M. Zuev. - 5th edition, revised. and additional - M.: Publishing center "Academy", 2011. - 288 p.

2. Andreev V.V. Inverter power sources for the welding arc // Welder, 2012. No. 6. pp. 25-29.

3. Smirnov V.V.: Equipment for arc welding. 2011

4. Chuloshnikov P.L. Study guide for prof. training. - M.: Mechanical Engineering, 2011.

5. Peshkovsky O.I. Manufacturing technology metal structures: Textbook. for technical schools.-- 3rd ed., revised. and additional - M.: Stroyizdat, 2012. - 350 p.

6. Kulikov O.N. Occupational safety during welding work. - M.: Academy, 2013.

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