Расчет расхода электродов при сварочных работах

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Molotplus
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электроды гост

Когда речь идет о больших производствах и крупных строительных проектах, без планирования не обойтись. Оно занимает значительную часть подготовки к работам. Планирование относится не только к финансовым расчетам и экономической составляющей будущих работ, но также к расходу тех или иных материалов, которые потребуются для создания крупной партии изделий, либо оборудования, или возведения определенной конструкции. Для того чтобы в дальнейших работах не было никаких сюрпризов со знаком минус, нужно тщательно все рассчитать и подготовиться.

Сегодня мы будем говорить о расчете расхода электродов. Давайте сразу расставим точки над “и” и сделаем пометку, что планирование расхода стержней актуально только для больших производств, где намечается большой проект. Для частного использования рассчитывать этот параметр не имеет смысла.

От чего зависит расход электродов?

Перед тем как углубляться в тему расхода электродов, нужно разобраться с тем, что конкретно оказывает влияние на этот показатель. Существует несколько характеристик, от которых он зависит:

  • длина шва и его глубина;
  • вес наплавленного металла, в отношении всей конструкции или изделия;
  • вес наплавленного металла в расчете на метр шва;
  • тип работ, которые предстоит провести.

Расходование электродов очень сложно подсчитать точно, поскольку на практике может возникать большое количество нюансов, которые будут положительно или негативно влияют на показатель. Однако есть методы, помогающие учитывать разные мелочи. Именно по ним и делаются расчеты расхода. Сейчас будем рассматривать суть таких расчетов.

Подсчет расхода на практике и в теории

Показатель расхода конкретной модели электродов — это табличное значение, однако оно может вычисляться и вручную. Это можно сделать двумя способами, которые могут применяться для разных материалов. Вот первый из них. Он имеет такую формулу:

H=M*K

М — это вес конструкции. К — коэф. расхода, который подставляется из справочной литературы. Он бывает равен от 1,5 до 1,9.

Второй метод использует такую формулу:

G = F*L*M

F — площадь поперечного сечения. L — длина соединения (шва). М — масса одного кубического см расходников.

Без таких теоретических расчетов обойтись очень сложно, и они обязательно должны присутствовать во время планирования, однако на практике на расход влияет множество других факторов. Это могут быть огарки, сила тока, напряжение, длина шва и т. д.

Погрешности, которые могут возникать при расчетах

Точно все подсчитать практически нереально. Как бы вы не старались все предусмотреть, в какой-то момент все может пойти не так, как планировалось изначально. Если учитывать моменты, из-за которых расход может измениться, получится сделать более точный прогноз по расходникам, нежели пользоваться только теоретическими выкладками. Вот что может повлиять на погрешность вычислений:

  • режимы сварки и используемые токи;
  • индивидуальные особенности электродов и материала;
  • мастерство и опыт сварщика.

Всегда, когда вы делаете подобные расчеты, необходимо закладывать в получившийся результат погрешность. Стандартное значение погрешности, которое можно использовать, равно 5 — 7%. Если после проведения работ и получения реальных цифр расхода, оказалось что допустимая погрешность превышена, значит в процессе произошли какие-то значительные сбои.

Даже если удалось максимально точно все просчитать, не сбрасывайте со счетов возможность, что в партии электродов будет небольшой процент бракованных стержней. Лучше сделать небольшой запас, чем сильно экономить и потерять в качестве.

Сколько стержней помещается в 1 кг?

Когда все цифры и показатели посчитаны и приведены к итоговому результату. Нужно начинать закупку расходников. В этот момент может появиться вопрос — какое количество упаковок нужно приобрести. Для того чтобы это определить, нужно точно знать сколько электродов содержится в одном килограмме. Эта мера является стандартной при реализации стержней. При подсчете нужно учитывать несколько параметров:

  • длина;
  • вес;
  • диаметр;
  • толщина упаковки.

Чем больше прутки по размеру, тем меньшее их количество будет содержаться в пачке. Как правило, средний вес можно узнать по диаметру прутка. Вот таблица, где приведены значения массы электродов, имеющих разные диаметры:

Диаметр, мм

 Средняя масса, гр

2,5

17

3

26

4

57
5

82

Как вычисляется расход на 1 т металла?

Кроме выяснения расхода, необходимо узнать какой расход показывают электроды в пересчете на 1 тонну металла. Этот параметр является очень важным, когда надо просчитать крупный проект. Норма расходов на 1 т металла отражает количество материалов, которые потребуются для работы. Этот показатель считается по такой формуле:

Н = М*Красхода

М — масса металла. Красхода — табличное значение коэф. расхода.

Какой стандартный расход имеют электроды?

Все нормы расходов можно “подсматривать” в таком документе, как ВСН 452-84 н. Но нужно помнить, что они могут изменяться, в зависимости от того, с каким материалом вы собираетесь работать, и условий в которых будет проходить сварка. Значения в этом документе могут использоваться для расчета номинального расхода. Мы рассмотрим таблицы и их значения далее.

Как посчитать расход на 1 м шва?

Такой показатель можно посчитать на самых разных сайтах онлайн. Для этого ресурсы предлагают калькулятор. В него нужно ввести несколько цифр и вы получите нужную величину.

Профессионалы с большим опытом любят считать все сами. Для этого они пользуются такой формулой:

Н = Нсв + Нпр + Нправ

Нсв — расход на сваривание. Нпр — расход на установку прихваток. Нправ — расход на правки, проводящиеся холостыми валиками.

Расход на проставление прихваток рассчитывается отдельно от прочих работ. Если толщина конструкции достигает 1,2 см, то он равен примерно 15% от основного расхода. Если толщина составляет более 1,2 см, значит показатель составляет около 12%.

Расчет расхода при сварке труб

Теоретический расчет этого показателя очень прост. Нужно просто разделить расход на метр шва на вес одного электрода. Получится количество стержней, которое потребуется для работы. Количество электродов умножается на метраж. Цифра, полученная при этих расчетах округляется в большую сторону.

Для получения показателя в килограммах, проводятся такие вычисления: объем раздела делится на плотность металла. Первый параметр — объем цилиндра (берется по большей стороне стыка). Полученное значение умножается на 1,4 — 1,8. Это поправка на возможные огарки.

Расход при сварке труб может сильно отличаться. Он будет зависеть от соединяемых стыков, а также от наличия и отсутствия стыков и скосов.

Как можно сэкономить материалы?

Существует несколько методов, с помощью которых можно сэкономить расход материалов и тем самым снизить свои затраты на расходники.

  • Для сварки нужно использовать полуавтоматы или автоматы. При ручной сварке потери могут вырасти до 5%. Чем лучше качество электродов, тем меньше потерь будет происходить.
  • Разные модели электродов работают с разными токами. Обращайте на это внимание и внимательно следите за режимами напряжения. Это поможет сэкономить расходники.
  • Очень важно соблюдать правильную технику сварки. Если работы ведутся под неправильным углом, расход может значительно вырасти.

Профессиональные мастера отлично знают под каким углом нужно работать и могут быстро определить это на практике. Перестроившись под нужные условия, они будут работать эффективно и экономно.

Помните, что правильный подбор электродов и соблюдение простых правил экономии, даст возможность серьезно выгадать в финансовом плане.

Таблицы расходов

Теперь познакомимся с таблицами стандартных значений расхода для различных электродов и типов работ.

Расход на килограмм наплавленного металла

Сварка углеродистых и низколегированных сталей

Тип Э42

Марка

 ВСЦ-4 ОЭС-23 АНО-6 АНО-17 ОМА-2

ВСЦ-4М

Расход, кг

 1,6 1,65 1,7

1,8

Тип Э42А

Марка

 УОНИ 13-45 УОНИ 13-45А
Расход, кг 1,6

1,7

Тип Э46

Марка

 Расход, кг

ОЗС-6

 1,5

АНО-13

1,6

ВРМ-26
АНО-21

1,65
АНО-4

1,7

АНО-24

АНО-34

ВРМ-20

МР-3

ОЗС-12

Тип Э46А

Марка

 УОНИ 13-55К

ТМУ-46

Расход, кг

 1,6

1,65

Тип Э50

Марка

 ВСЦ-3

55-У

Расход, кг

 1,7

1,8

Тип Э50А

Марка

Расход, кг

ОЗС-18

 1,5

ТМУ-21У

ОЗС-25

 1,6

ОЗС-28

ОЗС-33
АНО-27

1,65

ИТС-4

 1,7

УОНИ 13-55

ЦУ-5

ЦУ-7

Тип Э55

Марка

МТГ-02

Расход, кг

1,55

Тип Э60

Марка

 МТГ-01К ВСФ-65 ОЗС-24М

УОНИ 13-65

Расход, кг

 1,55

1,6

Сварка сталей с высоким содержанием легирующих компонентов

Марка

 Расход, кг

ОЗЛ-36

1,5
ЗИО-3

1,55

ЭА-898/19

 1,6

ОЗЛ-14А

АНВ-32

ЭА-606/10

 1,7

ЦТ-15

ЦТ-15К

ЦЛ-11

Сварка сталей, устойчивых к коррозии

Марка

 ОЗЛ-8 ОЗЛ-14 ОЗЛ-12 ЭА-400/10У

ЭА-400/10Г

Расход, кг

 1,7 1,75

1,8

Сварка сталей, устойчивых к высоким температурам

Марка

 Расход,кг
ТМЛ-1, ТМЛ-1У, ТМЛ-3У

1,5

ЦУ-2М, ТМЛ-3, ЦЛ-27А

 1,55
УОНИ 13-15М, УОНИ 13-ХМ, ЦЛ-39, ЦЛ-36, ЦЛ-40, ЦЛ-17

1,6

ЦЛ-26М, ЦЛ-41

 1,65
ЦЛ-6, ЦЛ-55, АНВ-1

1,7

ЦЛ-10

 1,75
ОЗС-11

1,8

Сварка разнородных сталей

Марка

 ИМЕТ-10 АНЖР-2

АНЖР-1, НИИ-48Г

Расход, кг

 1,3 1,6

1,7

Сварка жаропрочных сталей

Марка

 НИАТ-5, ЭА-395/9 ЦТ-10
Расход, кг 1,6

1,7

Соединения без скоса кромок

Положение шва Толщина металла, мм Зазор, мм Масса наплавленного металла, кг/1 м шва
Нижнее 1 0 0,02
1,5 0,5 0,02
2 1 0,03
3 1,5 0,05
4 2 0,13
5 2 0,16
6 2,5 0,21
7 3 0,28
Горизонтальное 1 0 0,02
1,5 0,5 0,03
2 1 0,04
3 1,5 0,07
4 2 0,17
5 2,5 0,2
6 3 0,25
7 3 0,33
Потолочное 4 2 0,08
5 2 0,13
6 2,5 0,14
7 3 0,16

Угловые соединения

Параметры Масса наплавленного металла, кг/1 м шва
Толщина металла, мм Сечение шва, кв. мм
2 2 0,03 0,02 0,03 0,03
3 4,5 0,05 0,05 0,05 0,06
4 8 0,07 0,07 0,07 0,08
5 12,5 0,1 0,11 0,11 0,13
6 18 0,15 0,15 0,16 0,17
7 24,5 0,2 0,21 0,22 0,25
8 32 0,26 0,27 0,28 0,32
9 40,5 0,33 0,34 0,36 0,4
10 50 0,4 0,42 0,44 0,5
11 60,5 0,49 0,53 0,57 0,62
12 72 0,58 0,62 0,66 0,73
15 113 0,91 0,97 1,04 1,11
18 162 1,31 1,37 1,49 1,6
20 200 1,62 1,62 1,78 1,98
22 242 1,95 2 2,16 2,39
25 323 2,58 2,6 2,9 3,18

Тавровые соединения

Параметры Масса наплавленного металла, кг/1 м шва
Толщина металла, мм Сечение шва, кв. мм
2 4 0,04 0,05 0,04 0,04
2,5 6,5 0,06 0,07 0,06 0,07
3 9 0,08 0,1 0,09 0,09
3,5 12,5 0,11 0,13 0,12 0,13
4 16 0,14 0,16 0,15 0,17
4,5 20,5 0,18 0,2 0,19 0,21
5 25 0,22 0,25 0,24 0,26
5,5 30,5 0,26 0,29 0,28 0,32
6 36 0,31 0,33 0,34 0,37
6,5 42,5 0,37 0,39 0,4 0,44
7 49 0,43 0,45 0,44 0,51
7,5 56,5 0,47 0,51 0,5 0,58
8 64 0,55 0,58 0,6 0,65
9 81 0,69 0,74 0,75 0,86
10 100 0,85 0,89 0,91 1,02
11 121 1,03 1,08 1,12 1,23
12 144 1,22 1,27 1,33 1,48
13 169 1,41 1,49 1,53 1,73
14 196 1,62 1,76 1,78 2,02
15 225 1,86 1,95 2,07 2,31

V-образные соединения (односторонние)

Толщина металла, мм Зазор, мм Масса наплавленного металла, кг/1 м шва
Положение шва
Нижнее 50 ° Нижнее 60° Вертикал 70° Потол 80° Гориз 60°
4 1 0,09 0,1 0,132 0,14 0,11
5 1 0,13 0,15 0,19 0,22 0,16
6 1 0,17 0,2 0,29 0,3 0,24
7 1,5 0,26 0,3 0,38 0,44 0,33
8 1,5 0,31 0,37 0,47 0,55 0,44
9 1,5 0,38 0,44 0,59 0,69 0,51
10 2 0,49 0,57 0,76 0,86 0,64
11 2 0,56 0,66 0,89 1,02 0,76
12 2 0,65 0,77 1,05 1,23 0,89
14 2 0,86 1,02 1,34 1,6 1,17
15 2 0,97 1,15 1,55 1,81 1,34
16 2 1,04 1,23 1,75 2,02 1,46
18 2 1,33 1,6 2,17 2,51 1,83
20 2 1,63 1,94 2,62 3,11 2,21
25 2 2,46 2,94 4 4,76 3,34

Первый и подварочный проход при V-образном соединении

Положение шва Толщина, мм Масса наплавленного металла, кг/1 м шва Диаметр электрода, мм
Нижнее 6-12 0,1 3
Нижнее больше 12 0,15 4
Вертикальное больше 8 0,15 3
Горизонтальное больше 8 0,15 3
Потолочное больше 10 0,1 3

Заключение

При необходимости провести работы дома, большой нужды в проведении расчетов по расходу нет. Планирование этого показатели важно для больших производств, которые выпускают изделия и оборудованием в промышленных масштабах. Для крупных предприятий, даже ошибка в 1% может стать большой потерей денег. Чтобы не допускать промахов, нужно внимательно просчитывать все показатели и стараться экономить материал. Для этого нужно хорошо настраивать оборудованием и соблюдать технику работ.

 

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