美國Phoenix 鋼鐵公司無縫鋼管廠采用Calmes軋管工藝，其軋管機組的平面布置圖是由意大利 Albert Calmes博士設計的，Phoenix 鋼鐵公司設計科在其他工程公司的配合下完成詳細設計，為了生產各種鋼號的優質無縫鋼管，使其內外徑和壁厚均具有良好的公差，軋管機組的設計以下列三方面內容為核心：Calmes在水壓沖孔機方面的專利、Calmes關于改進曼內斯曼延伸機方面的專利以及他所提出的周期軋管機的軋輥孔型。


  這(zhe)一軋管機(ji)組采用(yong)Phoenix 鋼鐵公(gong)司平爐頂(ding)鑄生(sheng)產(chan)的最大重量達8000磅的波浪形鋼錠為原(yuan)料，成品(pin)管直徑為51/2~16英(ying)寸(cun)壁厚為1/4~3英(ying)寸(cun)。


  這種軋(ya)(ya)(ya)管機組(zu)的一大特點是(shi)(shi)直接采(cai)用平爐(lu)鋼錠在(zai)一個(ge)連續的工(gong)藝過程(cheng)(cheng)(cheng)中軋(ya)(ya)(ya)制成管，并且僅一次加熱就(jiu)能完成沖孔、延(yan)伸，周(zhou)期軋(ya)(ya)(ya)管各工(gong)藝過程(cheng)(cheng)(cheng)，其(qi)主(zhu)要(yao)工(gong)藝過程(cheng)(cheng)(cheng)是(shi)(shi)：鋼錠清理(li)、加熱、沖孔、延(yan)伸、周(zhou)期軋(ya)(ya)(ya)管，再加熱、定徑、修磨，精整和水壓試驗，以下(xia)主(zhu)要(yao)論述沖孔、延(yan)伸和周(zhou)期軋(ya)(ya)(ya)管等三個(ge)工(gong)藝過程(cheng)(cheng)(cheng)。



1. 水(shui)壓沖(chong)孔


  鋼(gang)錠(ding)經火焰燒剝(bo)去(qu)除表面缺陷后(hou)，在(zai)車(che)底式(shi)加熱爐內加熱到2340~2370℉。用(yong)小(xiao)車(che)運送(song)到沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)機(ji)(ji)上(shang)(shang)進行(xing)沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)操(cao)(cao)作(zuo)(zuo)。鋼(gang)錠(ding)在(zai)1200t水(shui)壓(ya)沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)機(ji)(ji)上(shang)(shang)沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)，其操(cao)(cao)作(zuo)(zuo)過程如下：用(yong)水(shui)壓(ya)操(cao)(cao)縱的(de)(de)裝料機(ji)(ji)將鋼(gang)錠(ding)送(song)人沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)機(ji)(ji)，將其置于支架上(shang)(shang)的(de)(de)沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)位置，兩個(ge)支架中(zhong)有一個(ge)是固定(ding)(ding)在(zai)沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)模(mo)上(shang)(shang)的(de)(de)，而另一個(ge)則可以伸(shen)縮，沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)模(mo)前移時即將鋼(gang)錠(ding)套(tao)住(zhu)，開始沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)操(cao)(cao)作(zuo)(zuo)。鋼(gang)錠(ding)沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)后(hou)，其形狀(zhuang)像杯(bei)(bei)子，被(bei)(bei)稱為(wei)杯(bei)(bei)狀(zhuang)體(ti)，沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)模(mo)的(de)(de)內徑決定(ding)(ding)杯(bei)(bei)狀(zhuang)體(ti)的(de)(de)外徑。沖(chong)(chong)(chong)(chong)(chong)(chong)頭直徑則確定(ding)(ding)杯(bei)(bei)狀(zhuang)體(ti)內孔(kong)(kong)(kong)(kong)(kong)的(de)(de)直徑，圖(tu)13-1所示是沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)模(mo)前移但尚未套(tao)上(shang)(shang)鋼(gang)錠(ding)前端時的(de)(de)狀(zhuang)況，沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)模(mo)前移達到其沖(chong)(chong)(chong)(chong)(chong)(chong)程的(de)(de)75%,可伸(shen)縮支架從下部移出，圖(tu)13-2示出鋼(gang)錠(ding)已被(bei)(bei)套(tao)入沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)模(mo)內。


圖 13-1.jpg

圖 13-2.jpg


  圖13-3示(shi)出(chu)整個杯(bei)狀體(ti)還套(tao)在沖孔(kong)模內的(de)(de)情況，從圖13-3可以(yi)看出(chu)被(bei)沖孔(kong)的(de)(de)鋼錠前端(duan)只剩下很薄的(de)(de)杯(bei)底。鋼錠呈方形或圓(yuan)形，即直徑為13英(ying)寸(cun)(cun)，16英(ying)寸(cun)(cun)，19英(ying)寸(cun)(cun)和21英(ying)寸(cun)(cun)的(de)(de)波浪形圓(yuan)錠。


圖 13-3.jpg



2. 杯狀(zhuang)體延(yan)伸


在延(yan)伸機(ji)(ji)上(shang)，杯(bei)狀(zhuang)(zhuang)體在兩個在水平(ping)(ping)面上(shang)成反(fan)向傾(qing)斜的(de)斜置(zhi)軋輥間，通(tong)過(guo)具有一(yi)定形狀(zhuang)(zhuang)的(de)頂頭(tou)進(jin)行(xing)軋制。在垂直平(ping)(ping)面上(shang)有兩個固定導(dao)板，其(qi)作用是限制變(bian)形區的(de)杯(bei)狀(zhuang)(zhuang)體的(de)斷(duan)面形狀(zhuang)(zhuang)使之(zhi)不至于(yu)過(guo)分橢圓(yuan)。這種(zhong)延(yan)伸機(ji)(ji)與曼(man)(man)內斯曼(man)(man)斜軋穿孔機(ji)(ji)很相似，它(ta)可以延(yan)伸杯(bei)狀(zhuang)(zhuang)體，并穿透杯(bei)底使之(zhi)成為空心(xin)坯。


 圖13-4示出采用(yong)曼內斯曼輥型(xing)的延伸機對杯狀體(ti)進行延伸的過(guo)(guo)程。圖13-5所示是采用(yong)了Calmes軋輥的情況，空心坯延伸時，最好選(xuan)用(yong)延伸率(lv) λ＝1.75,最大不超過(guo)(guo)2。


圖 13-4.jpg


 延伸機(ji)采用3相、60Hz、功率為(wei)2208kW(3000馬力）的同步電機(ji)傳動，額定(ding)電壓(ya)、轉(zhuan)速分別為(wei)6900V,1500r/min,減速機(ji)的速比(bi)為(wei)3。


 延伸機的(de)主要特(te)點(dian)之(zhi)一是它所生產的(de)空心坯壁厚比較均勻(yun)。斜軋(ya)延伸機的(de)延伸過程可參看圖13-6。


圖 13-6.jpg


 杯狀(zhuang)體離開(kai)軋輥成為(wei)空心坯(pi)后，用(yong)以夾持頂桿的鎖門就打開(kai)，空心坯(pi)從(cong)延伸機輸出，用(yong)橫移小車將其運送(song)到周期軋管機。



3. 周(zhou)期軋(ya)管機軋(ya)管


  周期軋(ya)管機(ji)(ji)由一(yi)臺額(e)定(ding)功(gong)率(lv)為(wei)1472kW(2000馬(ma)力(li)）的(de)電動(dong)機(ji)(ji)傳(chuan)動(dong)，該(gai)電動(dong)機(ji)(ji)的(de)功(gong)率(lv)能達(da)2208kW(3000馬(ma)力(li)）而不至于過分發熱。電動(dong)機(ji)(ji)軸上配(pei)有(you)飛輪，在(zai)每一(yi)轉中它既提供能量(liang)(liang)(liang)又(you)獲得能量(liang)(liang)(liang)，軋(ya)機(ji)(ji)速(su)度是30~105r/min,較(jiao)低的(de)速(su)度用于軋(ya)制(zhi)大(da)管，而較(jiao)高(gao)(gao)的(de)速(su)度用來軋(ya)小管。操(cao)(cao)作喂(wei)料器(qi)的(de)高(gao)(gao)壓(ya)(ya)(ya)水(shui)(shui)壓(ya)(ya)(ya)力(li)為(wei)2800 Ibl/in或1500 Ibf/in,以向(xiang)一(yi)個前(qian)(qian)進缸和兩個回程(cheng)缸供水(shui)(shui)，正常運(yun)轉時(shi)(shi)(shi)，向(xiang)前(qian)(qian)進缸連續地供高(gao)(gao)壓(ya)(ya)(ya)水(shui)(shui)，向(xiang)前(qian)(qian)喂(wei)料時(shi)(shi)(shi)，高(gao)(gao)壓(ya)(ya)(ya)水(shui)(shui)由回程(cheng)缸流出(chu)，因此(ci)向(xiang)前(qian)(qian)喂(wei)料的(de)速(su)度受到(dao)從回程(cheng)缸排(pai)出(chu)的(de)高(gao)(gao)壓(ya)(ya)(ya)水(shui)(shui)量(liang)(liang)(liang)的(de)控制(zhi)。這一(yi)操(cao)(cao)作在(zai)咬(yao)人時(shi)(shi)(shi)是手工(gong)操(cao)(cao)作，由操(cao)(cao)作工(gong)自(zi)行控制(zhi)，軋(ya)制(zhi)時(shi)(shi)(shi)則是自(zi)動(dong)操(cao)(cao)作的(de)，操(cao)(cao)作工(gong)應(ying)使喂(wei)料器(qi)的(de)前(qian)(qian)進速(su)度與軋(ya)輥的(de)速(su)度同步；此(ci)外，操(cao)(cao)作工(gong)還必須控制(zhi)空(kong)氣(qi)壓(ya)(ya)(ya)力(li)p1,空(kong)心(xin)坯(pi)咬(yao)人時(shi)(shi)(shi)，迅速(su)把空(kong)氣(qi)從缸里排(pai)出(chu)，開(kai)始軋(ya)制(zhi)后，根據所(suo)軋(ya)管子的(de)規格(ge)調整空(kong)氣(qi)壓(ya)(ya)(ya)力(li)P1.液壓(ya)(ya)(ya)自(zi)動(dong)喂(wei)料器(qi)斷(duan)面示(shi)意圖如(ru)圖13-7所(suo)示(shi)。


圖 13-7.jpg


  該喂(wei)料(liao)(liao)器的(de)(de)一(yi)(yi)個特點是(shi)，空氣缸(gang)的(de)(de)沖程長(chang)度(du)都保持(chi)不(bu)變。軋(ya)制(zhi)152~203mm管子時(shi)(shi)沖程長(chang)度(du)為(wei)(wei)762mm,而軋(ya)制(zhi)228~406mm的(de)(de)管子時(shi)(shi)，則沖程長(chang)度(du)為(wei)(wei)838mm.這(zhe)意味(wei)著軋(ya)輥工(gong)作段長(chang)度(du)是(shi)恒(heng)定不(bu)變的(de)(de)，在軋(ya)輥車床上凸輪的(de)(de)安裝位置恰可(ke)使(shi)軋(ya)輥的(de)(de)工(gong)作段和所(suo)對應的(de)(de)喂(wei)料(liao)(liao)器一(yi)(yi)致。喂(wei)料(liao)(liao)的(de)(de)方向與(yu)軋(ya)輥旋(xuan)轉的(de)(de)方向是(shi)相反的(de)(de)，軋(ya)機操作工(gong)控制(zhi)喂(wei)料(liao)(liao)速度(du)并將(jiang)此速度(du)和軋(ya)輥轉速保持(chi)同(tong)步(bu)。芯(xin)(xin)(xin)棒(bang)長(chang)度(du)為(wei)(wei)4572~4877mm,同(tong)時(shi)(shi)使(shi)用的(de)(de)芯(xin)(xin)(xin)棒(bang)為(wei)(wei)5根(gen)，其中一(yi)(yi)根(gen)芯(xin)(xin)(xin)棒(bang)用于(yu)軋(ya)制(zhi)，其余(yu)芯(xin)(xin)(xin)棒(bang)在空氣中冷(leng)(leng)(leng)卻，然后浸人水(shui)中進(jin)一(yi)(yi)步(bu)冷(leng)(leng)(leng)卻，一(yi)(yi)般是(shi)3根(gen)芯(xin)(xin)(xin)棒(bang)在空氣中冷(leng)(leng)(leng)卻，一(yi)(yi)根(gen)芯(xin)(xin)(xin)棒(bang)在水(shui)里(li)冷(leng)(leng)(leng)卻，軋(ya)機運行(xing)中5根(gen)芯(xin)(xin)(xin)棒(bang)就這(zhe)樣反復(fu)循環著。


  根(gen)據所軋管子規(gui)格(ge)調下輥(gun)(gun)高(gao)度，調整后(hou)其高(gao)度是(shi)不(bu)變的(de)。當空心坯被(bei)軋成帶有皮爾(er)格(ge)頭(tou)的(de)管子后(hou)，應將上(shang)輥(gun)(gun)抬起。上(shang)輥(gun)(gun)是(shi)由高(gao)壓(ya)(ya)水缸來(lai)平衡的(de)，其升降由電動機(ji)操作，由于芯棒全長有1.6mm左右的(de)“退拔”，為使壁(bi)厚保持不(bu)變，軋制(zhi)時通過一(yi)個微調裝置而將軋輥(gun)(gun)升高(gao)，微調裝置由專用電動機(ji)和減速(su)箱(xiang)組成，減速(su)箱(xiang)的(de)出軸(zhou)通過空氣(qi)離(li)合器(qi)與壓(ya)(ya)下螺絲(si)電動機(ji)的(de)軸(zhou)相連(lian)，軋制(zhi)時操作工將上(shang)軋輥(gun)(gun)逐漸抬高(gao)以補(bu)償芯棒的(de)錐(zhui)度和熱膨脹。


  軋(ya)(ya)制(zhi)過(guo)程中(zhong)金(jin)屬流動的方(fang)向(xiang)與(yu)喂料的方(fang)向(xiang)相同(tong)，軋(ya)(ya)輥每轉(zhuan)一周后，芯(xin)棒(bang)回(hui)轉(zhuan)90°左右。當空心坯被軋(ya)(ya)制(zhi)并由(you)芯(xin)棒(bang)前端(duan)向(xiang)前移(yi)動時(shi)，毛(mao)管(guan)繼續在導槽上滑移(yi)，空心坯完全軋(ya)(ya)成管(guan)子后，上軋(ya)(ya)輥抬起(qi)，升降輥升起(qi)，將毛(mao)管(guan)輸送到熱(re)鋸(ju)，切(qie)去端(duan)頭和皮爾格頭，然后測(ce)量(liang)和稱(cheng)量(liang)管(guan)子，在管(guan)壁上標出(chu)測(ce)得的重量(liang)。