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鍛造水平分析 Forging level analysis


  中國鍛造行業(yè)是在引進、消化、吸收國外技術的基礎上發(fā)展起來的,經(jīng)過多年的技術發(fā)展與改造,行業(yè)中企業(yè)的技術水平,包括工藝設計、鍛造技術、熱處理技術、機加工技術、產(chǎn)品檢測等方面均有了較大提高。
 
 ?。?)工藝設計
 
  先進廠家普遍采用了熱加工計算器模擬技術、計算器輔助工藝設計以及虛技術, 提高了工藝設計水平和產(chǎn)品制造能力。引入并應用DATAFOR、GEMARC/AUTOFORGE、DEFORM、LARSTRAN/SHAPE和THERMOCAL等仿真程序,實現(xiàn)計算器設計和熱加工的過程控制。
 
  (2)鍛造技術
 
  40MN及以上的水壓機多數(shù)配備了100-400t.m主鍛造操作機和20-40t.m的輔助操作機,相當數(shù)量的操作機采用計算器控制,實現(xiàn)了鍛件鍛造過程的綜合控制,使鍛造精度可控制在±3mm,鍛件的在線測量采用激光尺寸測量裝置。
 
 ?。?)熱處理技術
 
  重點在于提高產(chǎn)品質量、提高熱處理效率以及節(jié)約能源、保護環(huán)境等。如采用計算器控制加熱爐和熱處理爐的加熱過程,控制燒嘴實現(xiàn)自動調節(jié)燃燒、調節(jié)爐溫、自動點火及加熱參數(shù)管理;余熱利用、熱處理爐配備再生燃燒室等;采用具有低污染能力和能夠有效控制冷卻的聚合物淬火油槽,各種水性淬火介質逐漸取代傳統(tǒng)的淬火油等。
 
 ?。?)機加工技術
 
  行業(yè)內(nèi)數(shù)控機床的比例逐步提高,部分行業(yè)內(nèi)企業(yè)設有加工中心,根據(jù)不同類型的產(chǎn)品配備了專有的加工機械,如五坐標加工中心、葉片加工機、軋輥磨、軋輥車床等。
 
  (5)質量保障措施
 
  國內(nèi)部分企業(yè)已配備最新的檢測儀表和測試技術,采用計算器控制數(shù)據(jù)處理的現(xiàn)代自動化超聲波探傷檢測系統(tǒng),采用各種專用的自動超聲波探傷系統(tǒng),完成各種質量體系的認證等。高速重載齒輪鍛件產(chǎn)品的關鍵生產(chǎn)技術不斷被攻克,并在此基礎上實現(xiàn)了產(chǎn)業(yè)化生產(chǎn)。在引進國外先進生產(chǎn)技術和關鍵設備的基礎上,中國已能自己設計和制造高速重載齒輪鍛件的生產(chǎn)裝備,這些裝備已接近國際先進水平,技術和裝備水平的提升有力的促進了國內(nèi)鍛造行業(yè)的發(fā)展。
 
 
  China forging industry is in the introduction, digestion, absorption of foreign technology on the basis of the development, after years of technological development and transformation of the industry's leading technology level, including process design, forging technology, heat treatment technology, machining technology, products Testing and other aspects have been greatly improved.
 
  (1) process design
 
  Advanced manufacturers commonly used thermal processing computer simulation technology, computer-aided process design and virtual technology, improve the level of process design and product manufacturing capabilities. Introduce and apply the simulation program such as DATAFOR, GEMARC / AUTOFORGE, DEFORM, LARSTRAN / SHAPE and THERMOCAL to realize the process control of computer design and hot working.
 
  (2) forging technology
 
  40MN and above the hydraulic press is equipped with a majority of 100-400t.m main forging machine and 20-40t.m auxiliary operation machine, a considerable number of operating machine using computer control, to achieve a forging process of integrated control, so that forging accuracy Control at ± 3mm, forging the on-line measurement using laser size measuring device.
 
  (3) heat treatment technology
 
  The focus is to improve product quality, improve heat treatment efficiency and energy conservation, environmental protection and so on. Such as the use of computer-controlled heating furnace and heat treatment furnace heating process, control the burner to achieve automatic adjustment of combustion, adjust the furnace temperature, automatic ignition and heating parameter management; waste heat utilization, heat treatment furnace equipped with regenerative combustion chamber, etc .; with low pollution capacity and can Effective control of the cooling of the polymer quenching oil tank, a variety of water-based quenching medium gradually replace the traditional quenching oil.
 
  (4) machining technology
 
  The proportion of CNC machine tools in the industry gradually increased, some enterprises within the industry with processing centers, according to different types of products equipped with a proprietary processing machinery, such as five coordinate processing center, blade processing machine, roll mill, roll lathe and so on.
 
  (5) quality assurance measures
 
  Some domestic enterprises have been equipped with the latest detection instruments and test technology, the use of computer control data processing of modern automated ultrasonic flaw detection system, using a variety of dedicated automatic ultrasonic flaw detection system to complete a variety of quality system certification. High-speed heavy-duty gear forging products, the key production technology has been overcome, and on this basis to achieve the industrial production. In the introduction of foreign advanced production technology and key equipment on the basis of China has been able to design and manufacture high-speed heavy-duty gear forging production equipment, these equipment is close to the international advanced level, the level of technology and equipment to enhance the promotion of the domestic forging industry development of.

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