Chapter 200: Crankshaft manufacturing

Such a powerful forging process is simply unprecedented.
It's a hydraulic press of 500,000 tons. The work ability is really strong.
Although there is no detailed test data. But Sheng Huainan believes that the quality of these seven spindles is absolutely beyond doubt.
Wang Bu'an, indeed has his own uniqueness!
Ordinary automobile crankshafts are all formed integrally. It is formed by extruding and cutting a large piece of alloy.
However, there is no way to form a very large marine crankshaft at one time.
No machine can forge a 22-meter-long marine crankshaft at a time.
It must be connected one by one.
Then high-strength precision welding.
The spindle is processed and it is the crank arm's turn.
Among the accessories for the spindle, the crank arm has the largest area, largest volume, and largest weight.
The machining difficulty of the crank arm is the most difficult.
The general five-axis CNC linkage machine tool is difficult to achieve.
The shape of the crank arm is irregular.
Different designs have different shapes.
Different shapes will lead to different performance. Therefore, its design requirements are very high.
At the same time, the crank arm needs to be connected to different spindles. Due to the different force directions, the strength requirements of the crank arm are very high. Basically, you can do as high as you can.
Otherwise, the spindle may have no problem during high-speed operation at full load. However, the crank arm may be broken.
In general, there are three basic shapes of crank arms.
rectangle.
Round.
Oval.
Generally speaking, the material utilization rate of the rectangular crank arm is the worst, and the mass and moment of inertia are larger. But it is easy to process and manufacture. Direct casting is sufficient. Mainly used for low speed and small batch crankshafts.
The circular crank arm structure is relatively simple, which is conducive to crankshaft balance. Convenient processing and manufacturing. The material utilization rate is inferior to the oval crank. It can be manufactured by forging or bar turning. Suitable for small batch crankshafts, especially multi-support crankshafts.
The elliptical crank arm has the most reasonable material utilization and high fatigue strength, but for free forging crankshafts, the crank shape needs to be processed by a mold. It is mainly formed by strong forging. Casting cannot provide sufficient strength. Suitable for various types of crankshafts.
There is no doubt that the elliptical structure is used for the main shaft of the super large ship. The requirements for forging are very high.
Generally speaking, the raw material of the crank arm must withstand a torsion force of at least 1200 Pa.
The crank arm after processing and forming needs to bear more than 100,000 tons of force as a whole.
If the strength is insufficient, it will crack.
Once the crank arm cracks, it must be replaced.
To replace the crank arm, the entire crankshaft must be removed. That would be a big trouble. Can't move for at least two months.
The weight of a crankshaft is as high as 500 tons. Is it easy to disassemble and install?
In addition, the oval weight is also troublesome.
The size of the weight is different.
The shape is different.
How to balance the weight requires precise calculation.
The shape of the counterweight is also irregular. It also requires a five-axis CNC linkage machine tool to process.
The issue is……
The crank arm is very big.
The counterweight is also very large.
For hundreds of tons of marine crankshafts, the weight of each crank arm is often more than ten tons.
The weight of a counterweight is often more than five tons.
Their strength requirements are still very high.
Before forming, it must be repeatedly forged.
If it is an ordinary five-axis CNC linkage machine tool, it can only be cut slowly. Little by little processing.
A counterweight often takes several days to cut.
Among them, the tool may need to be changed frequently.
After all, the strength of the counterweight itself is very high, and the tool wear rate must be very fast.
However, after forging the crank arm, it has not been completed yet.
On top of each crank arm, there are many accessories. You have to connect the spindle.
The gears, bearings, cavities, and perforations applied to each crank arm are different. The interface to the spindle is also different.
There are oil seal journals, connecting rod journals, oil holes, gear journals and so on.
The most troublesome thing is punching. The requirements are very high.
The steel used for the crank arm has a very high hardness. How easy is it to punch holes?
Moreover, if you are not paying attention when punching holes, it will affect the strength of the crank arm. If there is a hidden injury, it is tantamount to a disabled crank arm. Therefore, it is impossible to use ordinary drills. Even the hardest drill bit cannot be used to punch the crank arm.
So, what means should be used?
The only means is laser.
Ultra-high frequency laser. The thick crank arm is directly penetrated.
Make a small hole first.
Then cut and expand little by little.
However, it is a pity that the 500,000-ton hydraulic press itself does not have a laser drilling device.
Laser drilling, that is another set of configuration.
How to do?
simple.
The five-axis CNC machine tool comes with a powerful laser.
The laser of the machine tool is mainly used for cutting and surface finishing. But after parameter adjustment, it can also be used for punching.
"Is it really okay?" Pang Xihua was a little worried about gains and losses.
"Yes." Wang Bu'an replied affirmatively.
Doubt about the technology of Cybertron?
no need.
No, the crank arm is corrected in place.
The five-axis CNC linkage machine tool starts to simulate drilling. Determine the position of the hole and the frequency of the laser.
All this is done by computer simulation.
It will simulate the operation of the crank arm after punching and find out the problems.
Repeated simulation.
Repeated modification.
Until it is determined that there are no major defects.
At this time, it needs technical personnel to decide. If you think it's ok, then it really starts to punch.
Once you start punching, there is no chance to go back.
determine.
Confirmed for the second time.
Suddenly, a huge beam of light shot out.
With the crank arm thicker than 50 centimeters, a big hole appeared silently.
But the laser beam has easily penetrated.
"Ah!" Pang Xihua couldn't help but exclaimed.
"So fast?" The other technicians were also stunned.
They thought they needed to use a small laser to make a small hole first, and then gradually expand it.
Unexpectedly, others came up as a beam of light with a diameter of more than 20 cm.
In other words, how powerful is the laser transmitter?
How much energy does a beam of light exceeding 20 cm in diameter consume?
If it is driven by electricity, how much electricity is needed? How high voltage is needed?
If it is used to make a laser cannon, isn't it...
Unfortunately, nothing was answered.
Wang Buan felt that he had no need to answer.
Because the five-axis CNC linkage machine tool has its own energy. No external power supply is required.
In other words, no matter how powerful the laser transmitter is, it has nothing to do with other people. For technicians, there is no need to know.
"Connector……"
"It's not easy..."
A technician named Xie Liangzhe muttered to himself quietly. Very worried about Wang Bu'an.
The power of laser is so fierce, it is actually not good.
That is, the spindle interface is prone to errors.
There is no hole in the interface between the spindle and the crank arm.
The spindle only needs to be inserted half the depth of the crank arm. Just be able to do integral movement with the crank arm.
If the interface is punched through, it does not meet the requirements.
This requires adjusting the working depth of the laser.
It can only dissolve to a depth of 25 cm.
If it exceeds this depth, it is tantamount to failure.
Wang Bu'an began to adjust the parameters.
The huge beam of light broke out again.
A large hole was dented on the surface of the crank arm.
The depth of the big hole is exactly 25 cm. It is octagonal. It just matches the two ends of the spindle.
While drilling the crank arm, the five-axis CNC machine tool began processing gears and bearings.
It has a lot of auxiliary workbenches, which can start a dozen parts and components at the same time. Regardless of size and thickness.
The gear processing is not difficult.
The processing of the bearing is a bit more complicated.
The bearings are matched. Must be processed one by one.
The first thing to be processed is the ball.
The heavy cemented carbide was sent to the auxiliary workbench of the hydraulic press.
Start squeezing.
Extrude the alloy directly into a ball.
The original large piece of cemented carbide was stunned into the size of a volleyball.
Part of the cemented carbide is only the size of a tennis ball.
"Oh my God! Such a strong working ability!" Pang Xihua felt that his eyes were going straight.
What kind of processing technology is this?
What hydraulic capacity is this?
Could it be said that it is really 500,000 tons?
Otherwise, how can it be possible to press hard alloy to the size of a palm?
A small ball can weigh hundreds of catties. Horror to this level is simply unheard of. Don't say you have seen it.
After the ball is processed, it is the groove of the bearing and then the outer casing.
Then came the camshaft...
Then there are fasteners...
Fasteners include many. Including self-tapping screws, anti-loosening screws, hexagon socket screws, etc.
The specifications of each screw are different. Different gears and different bearings require screws of different specifications.
The biggest requirement of these screws is that they are very strong. The force of a single screw needs to exceed 10,000 tons. One can imagine how high their quality is required.
Previously, the screws used by Northern Heavy Industries were all from Kobe Steel. The price of each screw is equivalent to a Corolla car.
The price is barely bearable. The point is, there is still a long wait.
Kobe Steel itself does not just produce it.
It needs to adjust the production line.
Need to match the corresponding hydraulic press.
A large number of extrusion, cutting, quenching, and forging machinery are also needed.
Every ball is made through thousands of processes. It seems to be justified for the price of a Corolla sedan.
However, in Wang Bu'an, everything is so simple and rude.
extrusion.
Squeeze directly.
Transformers are so crude and direct.
Directly squeeze a heavy piece of hard alloy into the required ball.
Over there, the laser continues to punch holes.
This time, each oil hole is to be punched out.
The crankshaft needs a lot of lubricating oil. There must be an oil delivery hole.
The oil delivery hole must be inclined at a certain angle.
Obviously, the difficulty of this work is also very high.
The use of drills for machining requires consideration of chip removal. The metal dust must be cleaned out!
If there is powder residue in the oil hole, it will affect the lubrication effect.
Ordinary car crankshafts are processed by drills.
However, with Wang Bu'an, it is straightforward to save trouble.
Still laser.
adjust size.
Adjust the wavelength.
Adjust the angle.
A thin beam of light gently dissolves the oil holes.
The high-intensity laser directly melts the metal.
"I want it!"
"I want it!"
Pang Xihua finally blurted out.
He deeply believed that Wang Bu'an had not lied.
What he is currently showing is indeed a hydraulic press of 500,000 tons.
Only 500,000 tons of terrorist work capacity can squeeze the alloy into such a small mass. No hydraulic press of 80,000 tons can do it.
"The price is very cheap. It only costs 100 million yuan." Wang Bu'an said.
"Okay." Pang Xihua readily agreed.
The 500,000-ton hydraulic press was only sold for 100 million, and he definitely made a profit.
Do you know how much it cost for the 50,000-ton hydraulic press built by NHI? More than a billion. The performance is not as advanced as that provided by Wang Bu'an.
Others sell a hydraulic press and give a high-tech five-axis CNC machining center as a gift.
The capabilities of this machining center are also extremely powerful. The accuracy is 1 micron.
Due to the special purpose of marine crankshafts, the requirements for machining accuracy are also very high. It cannot be less than 50 microns.
How much is 50 microns? Basically it is equivalent to a fraction of the hair.
The accuracy requirements of marine crankshafts are so demanding.
The ship waits for the plane.
Machine isometric.
For Pang Xihua, this sentence was extremely impressive.
What does this sentence mean?
This means that shipyards must determine the supply of diesel engines before they dare to accept shipbuilding orders.
If you can't get the diesel engine, you can only watch the orders drift by in vain. Otherwise, if the hull is built but there is no matching diesel engine, it would be a tragedy.
Why is the diesel engine not in place?
Because there are not enough crankshafts.
Twenty years ago, only three companies in the world could produce super large crankshafts.
At present, the quantity is basically the same.
Wärtsilä.
General Electric.
Mitsubishi Heavy Industries.
There is no fourth one.
The crankshaft used by man was also processed by others.
For huge wheels of more than 100,000 tons, the large crankshafts required require a long delivery period.
However, if it is equipped with a 500,000-ton hydraulic press sold by Wang Bu'an and a five-axis CNC machine tool, it feels like a very large crankshaft can be produced in one day. The quality is unbeatable.
Xie Liangzhe couldn't help but said, "Chief Engineer Wang, since your industrial park is so efficient, why don't you give it to us directly?"
Wang Bu'an shook his head and said, "No. Mass production still depends on you."
He insists on principles.
The industrial park only produces raw materials~EbookFREE.me~ When necessary, it can show you the manufacturing process of samples to enhance your confidence.
However, mass production must be arranged separately.
Xie Liangzhe stopped talking regretfully.
Pang Xihua also felt a little regretful. Immediately, he was refreshed again.
Wang Buyan has already demonstrated to them.
The 500,000 tons hydraulic press is powerful.
Five-axis CNC linkage machine tools are also quality levers.
Since Wang Bu'an can use them to quickly produce crankshafts, why can't they?
They can't let Wang Bu'an show it!
The second one today. A few votes, thank you.
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