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山东鄄城黄河公路大桥是目前规模最大的波形钢腹板PC组合结构桥梁,也是国内首次大规模使用波形钢腹板的工程。在考察日本等国家波形钢腹板制造技术的基础上,分析了以往采用传统冷成型方法生产中厚钢波形钢腹板产生的各种缺陷及原因,在山东鄄城黄河公路大桥的波形钢腹板制作中,将传统工艺中多点同时受压改为仅在钢板的波峰或波谷的中央处用上模和底模将钢板夹紧,而从夹紧处用小半径辊轮向两侧碾压的方法,使钢板在非设计折角处不产生塑性变形,并且与传统加工方法相比在设计折角区域也仅产生很微小量的拉伸和压缩变形。该工艺避免了钢板因受拉引起的损伤和微裂纹等各种缺陷的产生,提升了产品各项质量指标,提高了生产效率,并延长了产品使用寿命。在制作山东鄄城黄河公路大桥波形钢腹板过程中,制定的产品质量控制指标对钢板矫正、喷砂、喷铝、喷漆这4个工序作了补充。按照该方法浙江中隧桥波形钢腹板有限公司已成功建造了拥有自主知识产权的冲压加工机组,并获得了18项专利。
Shandong Juancheng Yellow River Highway Bridge is currently the largest corrugated steel web PC composite structure of bridges, but also the first large-scale use of corrugated steel web project. On the basis of the research on manufacturing technology of corrugated steel webs in Japan and other countries, the defects and causes of corrugated steel webs produced by the traditional cold-forming method in the past were analyzed. The corrugated steel belts of Juancheng Yellow River Highway Bridge Plate production, the traditional process at the same time more pressure at the same time changed to only the crest or trough at the center of the die and bottom mold to clamp the plate, and from the clamp with a small radius roller to both sides of the mill The method of pressing allows the steel plate not to undergo plastic deformation at the non-design corners, and also produces only a small amount of tensile and compressive deformation in the design corner area compared with the conventional machining method. The process avoids a variety of defects such as damage caused by tensioning and micro-cracks in the steel sheet, improves various quality indexes of the product, improves the production efficiency and prolongs the service life of the product. In the process of making corrugated steel webs of Juan Juan Yellow River Highway Bridge in Shandong, the product quality control indexes formulated to supplement the four processes of steel sheet correction, sandblasting, aluminum spraying and painting. According to this method, Zhejiang Zhongguancun corrugated steel web Co., Ltd. has successfully built a stamping machine with independent intellectual property rights and obtained 18 patents.