西马克梅尔挤压机.pdf

page 1/26 1 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 production and process specification 生产工艺说明书生产工艺说明书生产工艺说明书生产工艺说明书 60 mn extrusion press line for steel tubes 60mn 钢管挤压机生产线钢管挤压机生产线钢管挤压机生产线钢管挤压机生产线 page 2/26 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 list of content 目录目录目录目录 page 页码页码页码页码 1. preface 3 引言引言引言引言 2. production program 4 7 产品产品产品产品大纲大纲大纲大纲 3. applicable standards 8 适用标准适用标准适用标准适用标准 4. basic material conditions 9 10 坯料条件坯料条件坯料条件坯料条件 5. technological process description 11 15 技术工艺描述技术工艺描述技术工艺描述技术工艺描述 6. general parameters and conditions 16 17 常规参数和条件常规参数和条件常规参数和条件常规参数和条件 7. general equipment data and design features 18 22 常规设备数据和设计特点常规设备数据和设计特点常规设备数据和设计特点常规设备数据和设计特点 requirements for building cranes 23 车间车间车间车间天天天天车要求车要求车要求车要求 8. general engineering and design information 24 xx 常规工程和设计信息常规工程和设计信息常规工程和设计信息常规工程和设计信息 page 3/26 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 1. preface 引言引言引言引言 the extrusion press line for stainless steel tubes is a production line for hot extrusion process of round ingots (billets) into seamless tubes. the ingot material are prepared and machined stainless steel billets with diameter from 176 416 mm, the hot extruded products are tubes in a range of outer diameter (ods) 48 273 mm. the extrusion line fabricates hot finished tubes as well as shells for high precision tubing by subsequent cold drawing and cold pilgering process. 该不锈钢管挤压机生产线是一条将圆铸锭（钢坯）挤压成无缝钢管的热挤压产线。坯料为 机件不锈钢，外径 176mm 到 416mm，挤出产品的外径范围在 48mm 到 273mm 之间。该 挤压产线依次通过冷拔和冷轧（皮尔格法）的处理，生产出成品管材和用于高精度管型材 料的毛管。 extrusion force is 60 mn, expanding force 25 mn. 挤压力为 60mn，扩孔力为 25mn page 4/26 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 2. production program 产品产品产品产品大纲大纲大纲大纲 2.1 general 常规情况常规情况常规情况常规情况 the extrusion line for steel tubes is designed in general for a range of production: 该钢管挤压产线一般来说是为下列范围的产品设计的： tube outer diameter 48 273 (325) mm 管材外径 wallthickness 3,5 35 mm 壁厚 extruded length 5 25 m 挤压长度 average cycle time: 75 sec 平均周期 definition of cycle time: 周期定义： cycle time is the time for loading of the billet loading into the extrusion press, upsetting, extrusion, decompression, hot cutting, container cleaning and mandrel cooling. the cycle time is measured from starting billet loader to stem into position for loading of new billet. the extrusion time is limited to 5 sec. if the extrusion time will exceed the limited time, the cycle time will change accordingly. 周期是指将坯料装进挤压机，墩粗，挤压，卸压，热锯切，挤压筒清洗和扩孔针冷却的时 间。该时间的计算是从启动装锭机到挤压杆就位准备挤压另一根新坯料。挤压时间限制为 5 秒，如果挤压时间超过限定的时间，周期时间也将相应地改变。 page 5/26 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 2.2 steel grades for production, deformability 用于生产用于生产用于生产用于生产，加工的钢种加工的钢种加工的钢种加工的钢种 the extrusion line covers the steel grades: 挤压产线包括以下钢种： low and middle carbon steel 低/中碳素钢 austenitic 奥氏体钢 austenitic-ferritic (duplex and super duplex) 奥氏体-铁素钢 （双相钢和超级双相钢） martensitic 马氏体钢 special grades (titanium, etc.) 特种钢种（钛合金等） due to the different steel grades, the deformability and extrusion temperature is related to the content of cr, ni, mo and other elements. for the hot forming extrusion process, the alloys can be classified as follows: 由于钢种的不同，变形和挤压温度与铬，镍，钼以及其他成分有关。对于热成型挤压工 艺，合金可以分为以下种类： group 组组组组 alloy 合金合金合金合金 typical grades 典型钢种典型钢种典型钢种典型钢种 1 low carbon steel 低碳素钢 1020 steel, etc. 2 low alloy steel (, etc.) 低合金钢 astm a-387, cr mo, cr13, etc. 3 austenitic and martensitic steel 奥氏体和马氏体钢 tp 304, 316, 316 l, 321, etc. 4 temperature and corrosion resistance steel 耐热和不锈钢 tp 316l, duplex 22-5, 25-7, high temperature steels, high mo-content tp316l, 双相 22-5， 25-7，高温钢， 高钼成分 page 6/26 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 2.3 raw material ingot dimension 原材料铸锭尺寸 the ingot material for the expanding press shall be in accordance to chapter 4. 扩孔机使用的铸锭应与第 4 章的规定一致 table billet dimensions 钢坯尺寸表： no. 序号 ingot billet od 铸锭外径 mm billet length for expanding press max 扩孔机坯料最大长度 mm billet od after expanding 扩孔后坯料外径 mm billet length max. 坯料最大长度 mm 1 176 800 184 1.000 2 236 900 244 1.200 3 296 1.000 306 1.300 4 346 1.000 356 1.300 5 416 1.000 426 1.300 ingot billet od: prepared billet, peeled and machined 铸锭外径： 准备坯料，剥皮和机加工处理 billet length for expanding press: max. billet length before expanding 扩孔机坯料长度： 扩孔前的最大坯料长度 billet od after expanding: billet od for extrusion press ? shell 扩孔后的坯料外径： 用于挤压机的坯料外径 billet length max.: max. billet length for extrusion press 最大坯料长度: 用于挤压机的最大坯料长度 page 7/26 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 2.4 product data 产品数据产品数据产品数据产品数据 2.4.1 general product data 常规产品数据常规产品数据常规产品数据常规产品数据 in chapter 8 the range of production against tube diameter and wallthickness are listed for a typical steel grade as tp 310/321 depending on billet size. 第 8 章中列出了以典型钢种 tp310/321 为例的产品范围（管材直径和壁厚），取决于坯料 尺寸。 2.4.2 productivity 生产力生产力生产力生产力 the productivity is based on the cycle of expanding and extrusion process. for each billet and billet length the number of billets can be assumed as following 8steel grade tp 310/321): 生产力是根据扩孔和挤压过程计算的。对于每根钢坯和钢坯长度以，可以确定钢坯数量， 以 tp310/321 为例： no. 序号 ingot billet od 铸锭外径 mm hole id 空内径 mm billet ingot length max 铸锭最大长度 mm billet ingot weight max. 铸锭最大重量 kg billets per hour 每小时坯料 根数 1 176 25 800 150 40 2 236 40 900 305 35 3 296 60 1.000 530 30 4 346 80 1.000 710 25 5 416 110 1.000 1000 20 page 8/26 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 3. applicable standards 适用标准适用标准适用标准适用标准 the tubes meet the requirements according to international standards as: 管材符合以下国际执行标准： astm 213 seamless ferritic and austenitic alloy steel stoiler, super heater and heat exchanger tubes astm 213 无缝铁素奥氏体双相合金锅炉管，过热器管和热交换器管。 astm 269 standard specification for seamless and welded ferritic and austenitic alloy steel tubing for general service. astm 269 标准规格无缝焊接铁素奥氏体双相合金钢管，用于一般用途 nfa 49-317 austenitic seamless steel tubes for engineering use nfa 49-217 奥氏体无缝钢管，用于工程用途 nfa 49-214 - austenitic seamless steel tubes for high temperatures nfa 49-217 奥氏体无缝钢管，用于高温环境 nfa 49-217 - austenitic seamless steel tubes for heat exchangers nfa 49-217 奥氏体无缝钢管，用于热交换器 din en iso 1127 stainless steel tubes din en iso 1127 不锈钢钢管 din 2391 seamless precision steel tubes din 2391 高精度不锈钢管 din 17459 austenitic seamless circular tubes for high temperature din 17459 奥氏体无缝圆形钢管，用于高温环境 iso 13680 petroleum and natural gas industries corrosion-resistant alloy seamless tubes for use as casing, tubing and coupling stock technical delivery conditions iso 13680 石油和天然气行业 用于保护外套，管型材料和连接器的不锈钢合金管 技术传送环境 page 9/26 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 4. basic material conditions 坯料坯料坯料坯料条件条件条件条件 in general, the basic material for stainless steel production are ingots with: 一般来说，生产不锈钢产品的坯料为经过以下处理的铸锭： melting with electric furnace, deoxidation and vacuum treatment for refining 钢坯需经电炉冶炼, 包括脱氧和真空条件清理 hot forming with suitable hot forming ratio (continuous casted, hot rolling, forged) 以适当的成型比热成型（连铸坯，热轧坯，锻造坯） internal structure: fine grain, clean structure, less size of internal inclusions, less or fail of delta ferrite content 内部结构：无大颗粒，结构整齐，含杂质面积较少，较少或没有铁素体成分 surface conditions: free of visible defects 表面情况：无可见的瑕疵 applicable standard for hot rolled round steel is din en 10 060 热轧圆形钢的适用标准为 din en 10 060 the basic ingot material for the hot extrusion process shall be machined with: 热挤压的坯料应经如下加工： surface: peeled or turned to achieve smooth surface conditions with ra = 3,2 m 表面： 剥皮或车削达到表面光滑 ra = 3,2 m defects: defects free, visible defects should removed by grinding 瑕疵： 无瑕疵，可见瑕疵应打磨除掉 cleanliness: surface free of oil- and grease, visible dust and dirt not acceptable, free of rust, colour, etc. 清洁度： 表面无油迹或油脂，可见灰尘或污垢不可接受，不可生锈也不可带颜色 all billets must be prepared for expanding and extrusion. the billets shall have the following preparation standard: 所有钢坯必须为扩孔和挤压做好准备。钢坯应执行如下准备标准: billet od: permissible tolerance +0/ -1,5 mm 钢坯外径： 允许公差+0/ -1,5 mm billet length: permissible tolerance 5,0 mm 钢坯长度： 允许公差 5,0 mm squareness of saw cut 1o to billet od 锯切面积 钢坯外径 1o page 10/26 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 out-of-roundness permissible tolerance 1,5 mm 不圆度： 允许公差 1,5 mm straightness: 1,0 mm/1000 mm 直度 1,0 mm/1000 mm chamfered edged: radius r= 40 60 mm with ra=1,6 m 倒楞: 半径 r= 40 60 mm with ra=1,6 m pre-drilled hole: hole diameter from 20 100 mm, 与钻孔： 孔直径范围从 20 到 100 mm pre-drilled hole eccentricity hole to center tolerance 0,3 mm 与钻孔偏心率 孔对于中心的公差 0,3 mm clean and oil-free surface (inner, outer) after preparation 钢坯准备好后表面干净无油（内部，外部） page 11/26 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 5. technological process description 技术工艺描述技术工艺描述技术工艺描述技术工艺描述 5.1 process flow chart 工艺流程图工艺流程图工艺流程图工艺流程图 the characteristical flow chart of the hot tube is as following: 典型管材生产流程图如下： ingot billet 钢坯钢坯钢坯钢坯 ? gas furnace 燃气加热炉 temperature 温度 700 - 800oc ? induction furnace 感应加热炉 temperature 温度 700 - 1150oc ? descaling 除鳞 ? lubrication 润滑 ? expansion 扩孔 ? shell 毛管毛管毛管毛管 ? re-heating 二次加热 temperature 温度 900 - 1250oc ? descaling 除鳞 ? lubrication 润滑 ? extrusion 挤压 ? tube 管材管材管材管材 ? ? water quenching 水淬火水淬火水淬火水淬火 cooling by air 空气空气空气空气冷却冷却冷却冷却 page 12/26 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 5.2 pre- heating 预热预热预热预热 the billets have to be transported from the billet stock into the pre-heating station by roller conveyor or overhead system. the pre-heating temperature for the billets shall be 900 -1150oc. 坯料需要通过辊道运输装置或悬空系统从坯料储存区运输到预热站。预热温度应为 900 - 1150oc pre-heating method shall be: 预热方法为： by roller gas hearth furnace 700 - 1000oc 辊底式燃气加热炉加热到 700 - 1000oc intermediate heating 900 oc to 1150oc shall be by horizontal or vertical induction heater 中间加热 900 oc 到 1150oc 应通过卧式或立式感应加热炉 heating tolerance for pre-heated billets 25oc. 坯料预热的偏差为 25oc 5.3 descaling 除磷除磷除磷除磷 after heating, the billets shall be free of scale. high pressure water descaling is recommended. 加热后，坯料表面应无磷。建议高压水除磷方法 5.4 lubrication for expanding process 扩孔加工的润滑扩孔加工的润滑扩孔加工的润滑扩孔加工的润滑 before loading ingot billet into the expanding and extrusion process, the billet has to be lubricated by glass powder. the lubrication has to fulfill two duties: 坯料在装进扩孔机和挤压机之前，需要用玻璃粉润滑。润滑处理起到以下两个作用： to build up a sliding film between billet and tools (container, die, etc.) 使坯料和挤压工具（挤压筒，模具等）之间产生一层光滑的膜层。 to prevent heat transfer from the hot billet to tools and therefore protection of overheating 防止温度从热坯料传递到挤压工具从而防止产生过热现象。 a glas lubrication fulfills these duties as an optimal lubrication tool. therefore, prior to the expanding and extrusion, the billet surface has to be lubricated on the entire outer and inner surface. for this reason, a glass lubrication table is located in front of the expanding and extrusion press. 为起到上述作用，玻璃润滑是比较理想的方法。因此，在扩孔和挤压之前，坯料的整个内 外表面都需要进行润滑处理。鉴于此原因，玻璃润滑台设在扩孔机和挤压机的前面。 page 13/26 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 the lubrication process for expanding is as follows: 扩孔机润滑工序如下: automatic lubrication of outer diameter by rolling process along the lubrication table 坯料外部自动润滑，沿润滑台滚动 automatic lubrication of inner diameter of billet by spoon inserted into the pre-drilled hole. 坯料内部润滑，通过安装在预钻孔内的抹砂匙 manual lubrication of cone with glass powder or glass pad 手动扩孔锥润滑，玻璃粉或玻璃垫 5.5 expanding process 扩孔加工扩孔加工扩孔加工扩孔加工 the pre-drilled billets ingots are loaded to the expanding press and expanded to final inner diameter of the tube. the expanding mode consists of loading the expanding cone to the expanding press the pre-drilled diameter to the final inner diameter of the tube. after expansion the billet is called shell. during expansion process a plug will be generate and shall be handled as scrap. 预钻坯锭装到扩孔机扩孔成内径管。扩孔模式包括：将扩孔锥安装到扩孔机上将预钻孔扩 孔成最终的内径管。经扩孔加工后的坯料称为毛管。在扩孔过程中的加工余量作为废料处 理 5.6 final heating 最终加热最终加热最终加热最终加热 after expanding the shells has to be re-heated to a temperature of 900oc 1250oc, so called final heating. after final heating, the shells are transported by a roller conveyor from final heating station to extrusion press. for a sufficient product quality the heating is one of the key figures of the tube extrusion process. therefore, it is recommendable that: 扩孔后，毛管需要再次加热到 900oc 1250oc,也叫最终加热。最终加热后，毛管通过辊 道运输系统运到挤压机的最终加热站。对于管材挤压加热处理是保证高质量产品的重要数 据之一，因此推荐： uniform and homogenous temperature distribution is essential 统一和均匀温度分布是至关重要的。 reliable temperature monitoring during complete process avoids overheating 可靠的温度监测全过程避免了过热现象的产生 fast transport to extrusion press of the billets after heating minimizes heat loss. 快速将加热后的钢坯运送到挤压机最大限度地减少热量损失。 heating tolerance for pre-heated billets shall be 15oc after soaking time. temperature gradient on length shall be 25 c at the exit of furnace after soaking-time. after heating, the billets shall be free of scale. page 14/26 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 均热时间过后，坯料预热公差应为 15oc，加热炉出口处坯料长度方向上的温度梯度应小 于 25 c 。加热后，坯料表面磷。 5.7 billet lubrication for extrusion process 挤压坯料润滑挤压坯料润滑挤压坯料润滑挤压坯料润滑 the billet surface has to be lubricated on the entire outer and inner surface. outer surface lubrication is being effected by rolling along the lubrication table which is covered with glas powder. inside lubrication is being effected by a spoon inserted into the expanded hole. 坯料的整个内外表面都需要进行润滑处理。外表面的润滑是通过坯料在玻璃粉覆盖的润滑 台滚动来实现。内部润滑使用的是安装在预钻孔内的抹砂匙。 for protecting the dies against overheating, a glass pad shall be placed in front of the extrusion die. the glas pads have to be fabricated with glass powder and sodium silicate. for each extrusion cycle one glass pad is needed. 为了防止模具过热，玻璃垫应设在模具前面。玻璃垫由玻璃粉和水玻璃制作。每个挤压周 期都需要一个玻璃垫。 the thickness of the glass coating as well as the grain size of the glass powder shall be adjusted due to billet alloy and billet temperature. 玻璃粉覆盖层的厚度以及玻璃粉颗粒的大小应根据坯料合金种类和温度作出相应的调整。 5.8 extrusion process 挤压挤压挤压挤压 the extrusion process includes the hot forming process of the expanded billet into hot finished tubes. the lubricated billets are fed into press centerline and shifted into the billet container. 挤压过程包括热成型过程（扩孔后的坯料制成管材成品）。将润滑处理后的坯料运送到挤 压机中心线上并移动到挤压筒内。 the extrusion stem speed should be arranged to have otain a defect free tube surface. 合理设定挤压杆的速度使钢管的表面无瑕疵。 the extrusion press as well as the vertical expending press has a central drive by hydraulic oil power station. this power station shall be located as close as possible to the presses. 挤压机和立式扩孔机的主要动力来源于液压油能源站。此能源站应尽可能地靠近挤压机/扩 孔机。 the auxiliary system of the extrusion and vertical expanding press handles the billet from the lubrication table into the press as well as from the expanding press into the roller table of the final heating station (scope of heater supplier). 挤压机和立式扩孔机的辅助设备为坯料处理提供动力：将坯料从润滑台运送到挤压机，从 扩孔机运到最终加热站的辊道上（加热设备供应商提供）。 page 15/26 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 the extrusion press has an automatic container cleaning device and mandrel cooling. the mandrel cooling shall be from inside of the mandrel, suitable for smaller mandrel ods, but also from outside for bigger mandrel diameters. 挤压机配有自动挤压筒清洗和扩孔针冷却装置。扩孔针冷却系统从穿孔针内部冷却，适合 较小外径的扩孔针，但对于较大直径的扩孔针，可从外部冷却。 5.9 tube handling after extrusion press 挤压机后端管材处理挤压机后端管材处理挤压机后端管材处理挤压机后端管材处理 the extruded tubes are handled by the runout system behind the extrusion press. after leaving the exit of the extrusion press, the tubes will handled as following: 挤出的钢管成品由挤压机后部的出料系统处理。钢管离开挤压机出口后，作以下处理： water quenching system, quenching within a certain time frame to avoid recrystallization 水淬系统，在特定的时间内淬火防止重结晶 air cooling on a cooling table 冷却台上空气冷却 after cooling and further downstream straightening, the tubes shall be cutted into finish or service lengths for further downstream processing. 冷却和下游拉直处理后，钢管被切成成品或供进一步深加工用的长度。 page 16/26 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 6. general equipment parameters and conditions 常规常规常规常规设备参数和条件设备参数和条件设备参数和条件设备参数和条件 all datas given are preliminary. 所有数据均为初步数据 6.1 general data for expansion press 扩孔机常规数据扩孔机常规数据扩孔机常规数据扩孔机常规数据 nominal expansion force 名义扩孔力名义扩孔力名义扩孔力名义扩孔力 25 mn operating pressure 工作压力 300 - 270 bar expansion 扩孔扩孔扩孔扩孔 expanding force 扩孔力 25,2 mn pullback force 回拉力 8,0 mn stroke 行程 2.000 mm speed, variable 速度，可调 50 - 300 mm/sec expanding diameter 扩孔直径 60 - 280 mm moving crosshead 移动梁移动梁移动梁移动梁 upsetting force 墩粗力 25,2 mn pullback force 回拉力 8,0 mn stroke for upsetting 墩粗行程 max 最大 1.500 mm upsetting speed, variable 墩粗速度，可调 50 - 200 mm/sec container 扩孔筒扩孔筒扩孔筒扩孔筒 container length 扩孔筒长度 1.400 mm ejecting force 顶出力 7,2 mn ejection cylinder stroke 顶出液压缸行程 1.500 mm page 17/26 xin xing ductile iron pipe co.,ltd. 新兴铸管有限公司 58700288 17.03.2009 6.2 general data for extrusion press 挤压机常规参数挤压机常规参数挤压机常规参数挤压机常规参数 nominal dynamical extrusion force 名义动力挤压力名义动力挤压力名义动力挤压力名义动力挤压力 60 mn operating pressure 工作压力 300 - 270 bar main ram and moving crosshead 主柱塞和移动横梁主柱塞和移动横梁主柱塞和移动横梁主柱塞和移动横梁 main ram force 主柱塞挤压力 38,0 mn advance force side cylinders 侧缸前进力 11,8 mn pullback force side cylinders 侧缸回拉力 5,7 mn total extrusion force 总挤压力 61,5 mn extrusion stroke approx. 挤压行程 大约 3.000 mm extrusion speed variable 挤压速度，可调 50 300 mm/s mandrel cylinder 穿孔针液压缸穿孔针液压缸穿孔针液压缸穿孔针液压缸 mandrel advance force 穿孔针前进力 11,8 mn mandrel pulback force 穿孔针回拉力 5,7 mn container 挤压筒挤压筒挤压筒挤压