With the rapid development of the national economy and science and technology, automobiles, trains, aviation and other transportation industries, mechanical forging process, the tonnage of equipment, precision, reliability and automation put forward higher requirements, especially with the rapid development of China's railroad industry, the speed of the train is constantly high, the original casting process such as the formation of train hooks, such as the quality of the large-scale key parts can not meet the train performance requirements must be changed to the forging process to improve the quality of parts, thereby ensuring high-speed, safe and reliable operation of the train. Train performance requirements, must be changed to forging process molding, in order to improve the quality of parts performance, so as to ensure that the train high-speed, safe and reliable operation. But because the largest domestic 25000kN double-disc friction press due to tonnage limitations is difficult to complete the heavy task, and imported equipment or hot-die forging crank press and expensive, the user is difficult to accept, therefore, the research and development of large-tonnage double-disc friction press is imminent. To this end, Qingdao Qingforging Forging Machinery Co., Ltd. engineers and technicians through a large number of theoretical calculations and simulation tests, creative development of the first domestic J53-3150 31,500kN large-scale double-disc friction press to meet the market demand. J53-3150 double-disc friction press is the largest tonnage of the series of presses produced by the international, the largest press in the country. Qingdao Qingforging Forging Machinery Co., Ltd. is the only manufacturer that has successfully developed the machine, which took only more than 3 months of processing, assembling and debugging, and was successfully commissioned and delivered to Nanjing for use. The successful development of the machine will provide many forging manufacturers with large-scale forging equipment with low cost, good performance, reliable quality and high level of control, thus saving investment and improving benefits for users. Application and development advantages (1) J53-3150 double-disc friction press has both the double characteristics and advantages of die forging hammer and hot die forging crank press. First of all, it has a certain impact in the working process, the slide stroke is not fixed, which is the characteristic of hammer equipment, making it possible to carry out many strikes of deformation in a groove, so that it can provide large deformation process (such as upsetting, extrusion, etc.) to provide large deformation energy and a certain forging force; at the same time, it is through the helical sub-transfer of energy, in the moment when the metal is plastically deformed, the force between the slide and the table is controlled by the closed frame of the press, which is the most important factor in the development of the press. The force is borne by the closed frame of the press and forms a closed force system, which is the characteristic of hot die forging crank press, thus it can also provide large deformation force and certain deformation energy for small deformation process (such as forging and die closing stage, fine pressing, embossing, etc.), so it can meet the force and energy requirements of various major forging and pressing processes. (2) Compared with the die forging hammer, the machine is equipped with a hydraulic ejector mechanism, which can carry out precision forging without die pulling inclination or small die pulling inclination, while the hammer does not have an ejector device, and the forging piece is completely taken out of the die by hand, and the forging piece must have a large die pulling inclination. Die forging on the hammer, not only poor accuracy, low pass rate, and high noise, serious environmental pollution, waste of energy, coupled with impact vibration, in the existing die forging hammer is difficult to carry out precision die forging. If the choice of hot forging crank press, you can solve the problem of precision, large-volume forging is more suitable for shaping, but the equipment investment is too large for the production scale of the batch is not large enough to choose the hot forging crank press is obviously uneconomical. (3) compared with the hot forging crank press, the machine is a fixed energy equipment, equipment stroke variable, there is no fixed dead center. Therefore, it is very convenient to adjust the mold, especially suitable for frequent mold replacement in small and medium batch forging production. The hot die forging crank press under the dead center is fixed, the stroke and pressure can not be arbitrarily adjusted, is not suitable for extension, roll extrusion and other production processes, the heating quality of the surface of the billet is also required to be higher, do not allow too much oxidized skin, especially when the operation of the equipment or mold adjustment is improper, as well as not allowed to discharging or overloaded use, there is a possibility of making the slide in the close to the dead center of the muffled and interrupt the production. (4) the machine striking force, generally allowed for the nominal force of 1.6 times, and hot forging crank press because of the easy "bogging" is generally allowed to use only 70% to 80% of its nominal force. Therefore, the same specifications of the press, double-disc friction press is the maximum striking force of hot crank press forging crank press 2 times, that is to say, J53-3150 type friction press is equivalent to 60,000kN of hot crank press working capacity of the mold. (5) the machine forging high precision, forging dimensional accuracy by the mold "hit by" and guide column guide (for precision die forging) to ensure that the equipment is not subject to its own elastic deformation of the impact of many factories in recent years have been the use of friction presses for precision die forging. (6) the machine boring time is short, only 1/2 for the hot die forging crank press, the heat transferred to the mold on the production is particularly important to ensure that the accuracy of each forging piece is basically the same. The hot die forging crank press due to the slider in the lower dead center near the slowest speed, not only the workpiece in the mold to stay a long time, short service life of the mold, and for some of the main way to fill the groove by pressing the forging, it is possible to produce a larger burr, but still not full of groove depth. (7) the machine structure is simple and reliable performance, sensitive and convenient operation, its equipment investment, mold costs and forging costs are cheaper than the die forging hammer and hot forging crank press more than half, compared with imported products, the performance is basically the same, but the price of imported products is only 1/4 of the Therefore, the theory and practice have confirmed that the J53-3150 double-disc friction press process to adapt to a wide range of forging parts of high precision, high productivity, moderate labor conditions, is a good choice. Moderate, good labor conditions, is in line with China's national conditions, with the international advanced level of large-scale precision forging equipment. Product structure design features of the domestic manufacturing friction press more powerful professional manufacturers are not many, but the newly established individual small factories, because of its limited development capacity, only rely on the surface imitation, and no quality system to ensure that the friction press made by different manufacturers, the key parts of the structural performance and quality of the big difference between the Qingdao Qingforging forging and pressing machinery Co. Ltd. production of friction press specifications and structure are also different, structural performance and quality is also improving, compared with similar products, J53-3150 type double-disc friction press in the structural design has the following advantages. Working principle screw upper end and flywheel rigid connection, the lower end is connected with the slider, by the copper nut will flywheel and screw rotary motion into the slider of the up and down linear motion, the motor through the pulley drive friction disk rotation, when the downward stroke begins, the right cylinder air intake, push the friction disk compression flywheel, rubbing the flywheel rotating, the slider downward, at this time, the flywheel accelerated and gain kinetic energy, in the moment before the impact of workpiece, the friction disk and the flywheel out of contact, slider disk and flywheel out of contact, the slider at this time with the speed of forging the workpiece, release energy until it stops; forging is completed, start the return trip, at this time, the left side of the cylinder air intake, push the left side of the friction disk pressed flywheel, rubbing flywheel reverse rotation, the slider is rapidly lifted to a certain position, the friction disk and the flywheel out of contact, the slider continues to free upward sliding to the braking stroke, the brake action, the slider Decelerate until it stops, in this way, the up and down movement 1 time, that is, to complete a work cycle. Main parts and components features and its role (1) the body adopts a combination of prestressed frame, divided into beams, columns and base, pre-tensioned by four high-quality alloy steel forged tie rods to become a single unit, high strength and rigidity of the frame, the body is designed as a combination of the first for the sake of lifting and transportation convenience, and the second is to improve product quality, to prevent the casting defects of the hidden dangers brought about by the casting; cross beams of the copper nut is made of a specially formulated high-quality wear-resistant copper alloy using a Centrifugal casting process made of copper nuts and above the guide sleeve is wearing parts, wear and tear need to be replaced in a timely manner; good lubrication of the spiral vice life is critical, must be adjusted according to the actual situation of lubrication in a timely manner to ensure that the spiral vice lubrication is sufficient; nut below the buffer ring is equipped with a buffer ring, when the brake fails, buffer ring is used to absorb the energy of the motion system, to avoid the movement of the system with the rigidity of the frame and damage to the machine, when it is found that When found on the impact of the buffer ring should immediately stop, and find out the reasons, troubleshooting, is strictly prohibited often on the impact of the buffer ring; work table on the cushion plate is used to protect the work table, can not be dismantled. (2) The transmission part adopts relatively easy high-speed cross-fork coupling type adjustment structure, the gap between the friction disk and the flywheel is generally 2~3mm, when more than 5mm should be adjusted in time to prevent damage to the relevant parts. Cross-fork coupling type adjustment structure from the anti-rust and anti-deformation aspects of the friction disk to effectively solve the problem of adjusting the friction disk, friction disk and drive shaft equipped with rust-resistant copper bushings, copper bushings are equipped with lubrication devices, need to be regularly injected into the oil and regular activities of the copper bushings, in order to prevent the oil from drying out the copper bushings are difficult to move, adjusting the friction disk, need to be tightened on the end of the friction disk locking nut, shall not be allowed to produce a gap in order to prevent the damage to the relevant parts of the tampering. Parts and components. (3) the use of slip insurance flywheel, thus ensuring that the equipment can output a larger strike energy, but also in the output of a larger strike force through the flywheel slip protection equipment. Flywheel outer edge of the cowhide belt for wearing parts, serious wear and tear should be replaced in a timely manner, the flywheel wheel body and upper and lower rims are equipped with slip friction plate between the bolts will be compressed, relying on the spring force of the disc spring will be friction coupled together, and play a role in safety and insurance, when the striking force exceeds the rated force, the upper and lower rims will be relative to the body of the wheel to slip, eliminating the excess energy, to avoid damaging the machine because of overloading, the slip insurance device shall not be arbitrarily locked, in order to prevent overloading. The slipping safety device shall not be locked to prevent overloading. Screw is the core part of the machine, its geometric accuracy, surface roughness and material performance is critical to its service life and even the service life of the copper nut. The screw is made of high quality alloy steel forging material, which is fully forged and detected, and then heat-treated to the appropriate hardness, so as to obtain the best comprehensive mechanical properties. Thread friction surface needs to be polished to reduce mechanical wear and improve service life. (4) The slider adopts X-type guide rail, with wear-resistant copper guide plate set on the guide rail surface, after the copper plate is worn out, the guide rail gap can be adjusted by adjusting the inclined iron to ensure the guiding accuracy of the slider, and the slider is equipped with spherical thrust bearings internally, which can transmit the striking force as well as self-aligning to ensure that the screw can withstand a certain degree of partial load, and the maximum eccentricity distance of this machine should be no more than 300mm.(5) Adopting the translational type of full-stroke brake, with high brake power, sensitive braking, and high braking power. Braking power, brake sensitive, safe and reliable, in the full stroke of any position can be achieved braking, through the slider of the point of movement so that the user to install and adjust the mold is very convenient. At the same time, the brake of panning type is light to the flywheel cow belt damage, and the service life of the cow belt is long. The size of the braking force can be realized by adjusting the cylinder compression spring, but too large braking force is not conducive to the service life of the flywheel cow belt. Therefore, in the case of meeting the requirements of use, do not adjust the braking force is too large. (6) hydraulic ejector, ejector force, ejector smooth, and ejector force and ejector stroke can be adjusted, ejector cylinder using composite structure, compact structure. When need larger ejector force, the size of the piston at the same time ejector, high efficiency; when the ejector force is small, only a small piston can eject the workpiece, the ejector rod is equipped with 3 rods, according to the needs of forging, can be used at the same time, can also be 1 rod or 2 rods used separately. (7) The manipulation adopts the structure of direct pushing by combined cylinder, which is simple and reliable, and fundamentally solves the problem that the fork manipulation is easy to break and difficult to maintain. (8) The main lubrication point adopts full-automatic centralized lubrication, thus avoiding the problem of operating the screw vice due to untimely and insufficient lubrication caused by human factors. The amount of oil should be adjusted according to the field work. (9) platform rigidity, low vibration, low noise, easy to use front and rear through, beautiful appearance and no safety devices to ensure the safety of maintenance personnel. (10) the main control components of the control system using Japan's OMROW production of CQMIH programmable controller (PLC), the modular design, compact structure, advanced control lines, sensitive adjustment, reliable operation, easy to use and maintain, the machine's striking energy can be adjusted by adjusting the manipulation of the cabinet on the time relay to adjust. There are no two kinds of working states for machine adjustment and automatic operation, the adjustment working state is used for machine adjustment or mold adjustment, the automatic working state is used for normal use of the machine, and after the mold adjustment is completed, the automatic working state can be used for workpiece striking. In addition, the machine operating cabinet is equipped with optional tonnage monitor to automatically monitor the actual size of the blow force, if the blow force exceeds the maximum allowable value, the monitor will automatically alarm and automatically stop the work to protect the safety of the equipment, in the main machine operating area users can also choose to install photoelectric protection devices to further ensure the personal safety of the operator. Typical forging application examples The product is mainly used for die forging, upset forging, straightening, fine pressing and other molding processes for large forgings, which can be widely used in train, automobile, tractor, ship, aviation, hardware tools, medical equipment, tableware, machinery manufacturing and other industries. (1) Forming of large forgings such as train towing hooks, front caps of copper air vents, and shovel teeth of construction machinery. These parts were originally made by casting process, but with the increasing competition in the market, the user of the product safety, reliability and service life put forward higher requirements, the traditional casting production methods have been challenged, casting defects are becoming more and more prominent, there is an urgent need to replace the casting of forging molding, thus improving product quality, to ensure that parts and components of the use of safe and reliable. (2) Top upsetting forgings. This kind of forgings generally require head local upsetting forming, the rod is not deformed. (3) large gears and other cup and plate forgings such as Fujian Jinjiang Qingma Forging Factory 400mm large gears originally used 5t hammer forging, in order to improve the labor conditions, is now 25000kN friction press instead of hammer die forging, larger specifications of the gears will be used 31500kN friction press instead of hammer die forging, so as to improve labor productivity and energy saving. (4) axles, crankshafts, ring head screws, automobile engine connecting rods and other long shaft forgings. Hefei Forging Plant and Liaocheng Forging Plant were on a car front axle forging line, with JA53-100B, JA53-1600A and JA53-2500A wide table double-disc friction press instead of hot forging crank press, the quality of automotive front axle and daily output can be comparable to the 10,000 tons of hot forging production line, but less than 1/2 of the investment in hot forging, the overall efficiency is very prominent, the success of the experience is worthwhile Successful experience is worth learning. Guangzhou Railway Parts Factory, using friction presses have the characteristics of the top material device, the ring first class bolt forging process has been improved, using friction press forging instead of hammer on the tire die forging, simplified the process, improve labor productivity, saving electricity, fuel. The original use of the hammer on the tire die forging, 4 people need to work with the daily output of 450 pieces, now using friction press die forging, 3 people work with the daily output of 900 pieces, which can improve labor productivity by about 2 times, and optimize the labor conditions, improve the service life of the mold. Practice has proved that the friction press die forging ring first class bolt forging technology program is economic and reliable, energy saving, improve labor productivity, reduce labor intensity. Engine crankshaft original die forging on the 5t hammer requires 6 to 7 strikes to form, forging qualified rate of only 60% to 65%, and in 31500kN screw press only need to pre-forging and final forging 2 times to form, reduce the labor intensity of the operator, reduce environmental pollution, each piece of saving 1.15 kg, qualified rate of nearly 100% per day can be produced nearly 1,000 pieces, die life is greatly extended, the quality, Efficiency and energy-saving indicators have been greatly improved. (5) Can be forged flange, three-way valve body and other forgings with two flanges or pits. (6) Precision forgings such as blades, bevel gears, etc. can be realized on the friction press with less cutting. For example, Shaanxi Blower (Group) Co., Ltd. original use of free forging hammer forging turbine compressor blade, forging allowance is large, not only waste of materials and high processing costs, change to use friction press precision forging, material utilization rate by 10% of free forging, increased to more than 50%, because precision forging blade unilateral allowance is generally not more than 1mm, the line does not need to be imitation machining and can be directly ground to save a lot of machining time, improve production efficiency, and basically maintain a small amount of cutting process. Improve the production efficiency, and basically maintain a complete forging flow line, so that the strength of the blade is also increased by more than 10%. And with double-disc friction press forming can be used block mold, die base for universal parts, forging different specifications of the blade only need to replace the block die, thus simplifying the debugging of the mold, and reduce manufacturing costs. Conclusion of China's many forging manufacturers, a large number of equipment, but the overall technical level is not high, a large number of old forging hammers are small and medium-sized forging enterprises of the leading equipment, the urgent need to upgrade, especially in the production of large-scale precision forgings of modern enterprises, the backwardness of the system of equipment chickens with the level of industry, efficiency and forging the quality of the improvement of the development of the market economy, energy saving, energy-saving, high-quality, high efficiency has become the development of modern forging plant At the same time, a large number of forging plants due to equipment selection and process characteristics, production does not match and cause a serious waste of equipment resources, forging cost is too high. Therefore, according to their own forging process characteristics and production selection of forging equipment suitable for their own, should be given full consideration, thereby saving investment to improve efficiency.
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