中国8万吨锻压机:三分半钟可造飞机起落架
2013年04月11日 12:07 成都商报
国之重器
  大型模锻压机是衡量一个国家工业实力的重要标志。迄今为止,仅有美国、俄罗斯、法国3个国家有类似设备,最大锻造等级为俄罗斯的7.5万吨,而我国的达8万吨
  世界第一
  总高42米,重约2.2万吨,单件重量在75吨以上的零件68件,压机尺寸、整体质量和最大单件重量均为世界第一。这是中国二重历时10年打造的世界“重装之王”
  昨日,中国二重举行8万吨大型模锻压机试生产暨产品推介会,向用户、合作伙伴展示“国之重器”的建设及产品服务情况。从2003年8万吨大型模锻压机申请立项,中国二重开始了10年的追梦历程,在吸收、消化、再创新的基础上,二重突破超大、超长、超重零部件的极限制造,实现了最新技术与固有技术的结合,成功研制出8万吨大型模锻压机,使中国成为拥有全球最高等级模锻装备的国家。
  8万吨锻压机“德阳造”
  昨日上午,中国工程院院士钟掘、中国科学院院士曹春晓以及来自中国航空工业集团公司、中航发动机控股有限公司、沈飞工业集团、成飞工业集团等50多家国内大型企业负责人出席了推介会。
  院士钟掘说:“8万吨大型模锻压机投入试运行,将我国高端重大装备的制造能力托举到国际顶级水平,也为中国走向制造强国掀开了历史性的一页。”
  8万吨大型模锻压机列装后,我国航空航天等最难做的大件,动力发电、海洋工程、西气东输、深部开采等各行各业要用的性能最高的、尺寸最大的、结构最复杂的构件都能通过该锻压机完成。
  “如果说以前生产锻件需要千锤百炼,那么有了8万吨大型模锻压机则是一锤定型。”8万吨大型模锻压机项目常务副总指挥、中国二重副总工程师陈晓慈形象地比喻,该锻压机是通过强大的压力作用,使性能普通的金属材料在模具内流动,细化内部晶粒,实现大型模锻件的整体精密成形,这些金属材料可以蜕变为飞机的“骨骼”———框梁,可以蜕变为发动机的“脊柱”———涡轮盘,可以蜕变为油田的“血管”———输油管三通等。陈晓慈将运行原理比喻为“压月饼”,通过液压传递能量形成压制力,并解决一次性成型问题。
  3分半钟搞定一个飞机起落架
  在二重集团厂大型压机车间里,一台巨型机器摆在眼前。这台大型模锻压机是航空、航天、石油、化工、船舶等领域所需模锻件产品的关键设备。地上27米,地下15米,总高42米,相当于13层楼高,重约2.2万吨,单件重量在75吨以上的零件68件,压机尺寸、整体质量和最大单件重量均为世界之首。
  昨日上午10时许,在众多专家的见证下,机械启动,机械手从高温箱里缓慢夹起一个类似“丫”字形状的锻件,它浑身散发着橙色的光,一股热气袭来,随即,机械手将其送至10多层楼高的模锻压机的锻压台。“轰、轰、轰”的一阵响声之后,锻压台面合拢了,一簇火团从缝隙中“哗”地蹦了出来,伴随着不断飞溅的火花。
  参观人员屏住呼吸,目不转睛地盯着锻压台,锻压台台面缓缓张开,一个用于国产某型号商用飞机起落架的大型锻件产生,整个过程3分半钟,观摩的人群顿时响起热烈的掌声。“报告,8万吨模锻压机首件试压成功!”戴着黄色安全帽的技术员说。在现场,中国锻压协会航材委主任委员曾凡昌激动地说:“搞了一辈子航空大锻件,今天终于梦想成真了。”
  十年磨一剑 打造“国之重器”
  早在上世纪70年代末,二重人就开始筹划设计制造大型模锻压机。陈晓慈此前公开接受媒体采访时表示,压力必须是4万吨级以上,才能称之为大型模锻压机。
  据中国二重的一份资料显示,在8万吨模锻压机诞生前,我国还没有4万吨级以上的大型模锻压机,而目前世界上拥有4万吨级以上大型模锻压机的国家只有美、俄、法3国,目前最高吨级为俄罗斯7.5万吨。
  1980年9月26日,中国首次自行研制制造的大型喷气式客机“运-10”首次试飞成功后,试飞累计170小时后停留于地面,“其原因很大程度上与当时中国没有能加工大型机身大梁所必需的大型模锻压机有关。”陈晓慈介绍,由于无法用大型模锻压机对飞机大梁整体锻压成型以确保质量,就只能用小型设备分段锻造、组合拼装,这无法满足大飞机所要求的质量标准。
  2003年,受国务院委托,30多人的专家组调研论证,并通过对空客、波音飞机的分析,认为7.5万吨级模锻压略显功能不足,最终将压力量级定在8万吨。2007年11月15日,大压机计划最后批复落户二重。论证5年,建造5年,可谓10年磨一剑。“至少上千人参与了建造。”陈晓慈感叹。
  2012年4月1日,中国二重独立自主设计、制造、安装的世界最大的8万吨模锻压机热负荷试车一次成功。昨日,8万吨大型模锻压机成功试生产。“这是一个集机、电、液为一体的巨系统工程,成功挑战目前人类极限制造能力。”陈晓慈介绍。这台设备制造成功的本身,是很多新技术、新工艺的突破,可扩展应用于其他多种领域,它还将辐射带动一批庞大的航空构件的机械加工集群,形成整机设计、整机制造和发动机制造的闭合产业链。
news.sina.com.cn
China's 80,000 tons forging-pressing machines: three and a half minutes to make an airplane landing gear
At 12:07 on April 11, 2013 Chengdu Business Daily
Heavy Equipment of the Nation
Large forging-pressing ability is an important symbol to measure a country's industrial strength. To date, only three countries in the United States, Russia, France and similar equipment, the maximum forging-pressing level of 75,000 tons for Russia, while China's 80,000 tons
The world's first
The total height of 42 meters and weighs about 22,000 tons, 68 one-piece parts weighing more than 75 tons, press size, the overall quality and the largest single piece weight are the first in the world. This Chinese double lasted 10 years to build the world reload the king "
Yesterday, the Chinese double held 80,000 tons of large forging presses trial production and product promotion, to users, partners demonstrate the building of the State of the weighing and products and services. Project application large forging presses from 80,000 tons in 2003, China re-start the course of 10 years of Dream in absorption, digestion, based on a new, oversized double breakthrough, long, overweight limit of parts manufacturing to achieve a combination of the latest technology and the inherent technology, the successful production of 80,000 tons of large forging presses, making China the country with the world's highest level of forging equipment.
80,000 tons forging-pressing machine made in Deyang
Yesterday morning, the Chinese Academy of Engineering Zhong Jue, the person in charge of the Chinese Academy of Sciences Cao Chunxiao from the China Aviation Industry Corporation, China Aviation Engine Holdings Limited, Shenyang Aircraft Industry Group, flying into the industrial group, more than 50 large domestic enterprises attended the promotion .
Academician Zhong Jue said: "80,000 tons of large forging presses put into trial operation, the major equipment manufacturing capability of China's high-end lifts to the top international level, but also opened a historic chapter in China to manufacture power."
80,000 tons of large forging presses fitted out, the most difficult to do large of China's aerospace, power generation, marine engineering, natural gas, deep mining and other industries to use the highest performance, size, the most complex component can be completed by the forging press.
"If the production forgings tempered, with 80,000 tons of large forging presses a hammer stereotypes. 80,000 tons of large forging press project executive vice commander, liken Chinese double, deputy chief engineer Chen Xiaoci,, The forging machines by strong pressure, so that the general performance of the metal material flow in the mold, to refine the internal grain to achieve the the large die forgings overall precision forming, these metal materials can be transformed for the aircraft "bone" --- box beam can be transformed to the "spine" of the engine --- turbine disk can be transformed for the oilfield "vascular" --- pipeline tee. Chen Xiaoci operating principle compared to the pressure moon cake "hydraulic energy transfer to form a pressing force, and solve a one-time molding problems.
3 and a half minutes to get an aircraft landing gear
In the the large presses workshop of the two-group plant, a giant machine in front of us. This large forging presses the fields of aviation, aerospace, petroleum, chemical, shipbuilding and other key equipment required for die forging products. On the ground 27 meters, 15 meters underground, the total height of 42 meters, the equivalent of 13 stories tall, weighing about 2.2 tons, 68 one-piece parts weighing more than 75 tons, press size, the overall quality and the largest single piece weight as the first in the world.
10 o'clock yesterday morning, in the witness of many experts, the machine will start, slow to pick up a similar "Ah" shape forging manipulator box from the high temperature, it exude orange light, a surge of hot air hit, then, robot will be sent to the 10 multi-story forging presses forging station. "Boom, boom, boom" after the burst of sound, forging the countertops close, a bunch of fireball from the cracks in the "Wow" to jump out, along with the constantly flying sparks.
The visitors breath, staring at forging forging countertops slowly open, one for a particular model of the domestic large commercial aircraft landing gear forgings, the whole process three and a half minutes to observe the crowd suddenly burst into warm applause. Report, 80,000 tons forging presses successful pressure test! "Said technician wearing a yellow helmet. In the field, China Forging Association Air Materiel Committee chairman Cengfan Chang said excitedly: "engage in a lifetime of aviation forgings, is finally a dream come true."
Decade of grinding sword to create the "State of the weighing"
As early as the end of the 1970s, Shigehito to start planning the design and manufacture of large forging presses. Chen Xiaoci had public interview with the media, the pressure must be more than 40,000 tons, can be called large forging presses.
According to the double an information display, before the birth of the 80,000 tons forging presses no more than 40,000 tons of large forging press, while the countries of the world with more than 40,000 tons of large forging presses only three countries in the United States, Russia, France, the highest-ton to 75,000 tons from Russia.
September 26, 1980, China's first self-developed manufacturing jumbo jet transport Y-10 "after a successful maiden flight, after accumulated 170 hours of flight stay on the ground," largely due to China was not able to processing the large fuselage beam necessary for large-scale forging presses relevant. "Chen Xiaoci introduced large forging presses can not the aircraft beam as a whole forging molding to ensure quality, we only use a small device sub-forging, the combination of assembly, this can not be meet the quality standards required by large aircraft.
In 2003, commissioned by the State Council, the group of experts in more than 30 research and demonstration, and that the 75,000-ton die forging slightly Airbus, Boeing aircraft, function, and eventually the pressure magnitude is set at 80,000 tons. November 15, 2007, a large press was finally approved the settled heavy. Demonstration of five years, the construction of five years, can be described as "10 years of forging a sword". "At least a thousand people were involved in the construction of," Chen Xiaoci sigh.
April 1, 2012, the double independent design, manufacture and installation of the world's largest 80,000 tons forging presses heat load test a success. Yesterday, 80,000 tons of large forging presses successful trial production. "This is the the giant system works as one of a set of mechanical, electrical, hydraulic, successfully challenged the limits of human ability to manufacture" Chen Xiaoci introduced. Device manufacturing success itself, a lot of new technology, new technology breakthrough, scalable used in a variety of other areas, it will also radiation and leading a group of large aerostructures machining cluster, forming machine design, machine manufacturing and engine manufacturers closed industrial chain.
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