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Design of titanium forging workshop

2009-04-08View Original

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A hammer or press is used to apply blows or pressure, causing plastic deformation. The forging process is determined based on the forging properties of the alloy, the shape of the product, the technical requirements, and the capabilities of the forging equipment. The main processes in forging include ingot preparation, blanking, heating, forging, and surface finishing, among which most of these processes need to be repeated. Equipment selection includes heating furnaces, forging machines, surface repair equipment, and sawing equipment. Titanium and titanium alloys in heating furnaces can be heated in resistance furnaces or oil or gas furnaces with a micro-oxidation atmosphere. The commonly used heating furnaces are of the car-type and chamber-type. Trolley-type oil or gas furnaces are suitable for heating before ingot blanking or during intermediate heating steps for large-sized forgings; chamber-type oil or gas furnaces are appropriate for heating small and medium-sized forgings; chamber-type resistance furnaces are suitable for heating before final forging when strict requirements are imposed on the heating process. To utilize the capabilities of the main machine and ensure product quality, it is often necessary to equip a single main machine with several types of heating furnaces in order to meet the heating requirements of various blanks. Equipment used for forging titanium and titanium alloys in forging machines includes air hammers, steam hammers, and forging hydraulic presses. Forging water presses are commonly used for ingot opening and forging of large-section billets, while forging hammers can be used for billets with smaller sections; for billets with a side length of less than 100 mm, air hammers are preferred for forging. Since the 1970s, rapid forging hydraulic presses have developed rapidly, with a forging frequency of over 100 times per minute. It retains the static-pressure forging characteristics of conventional hydraulic presses, while also offering the advantage of fast hammering action. It features high production efficiency, product quality, and dimensional accuracy; in forging equipment with a capacity of less than 30MN, it has gradually replaced conventional forging hydraulic presses. Due to the high deformation resistance of titanium alloys and the narrow forging temperature range, forging equipment must have greater capacity than that required for forging carbon structural steel of the same specifications, allowing for a higher number of forging operations per unit time. The forging workshop needs to be equipped with forging manipulators and loading/unloading machines. Operation machines and loading/unloading machines are divided into tracked and trackless types; tracked types are commonly used for operation machines, while trackless types are commonly used for loading/unloading machines. The capacity of the handling machine and the loading/unloading machine can be determined based on the weight and geometric dimensions of the ingot billet; alternatively, the capacity of the handling machine can be chosen according to the capacity of the forging equipment. When the nominal pressure of the forging hydraulic press is 7.8–9.3 MN, the capacity of the operating machine is usually set at 5–10 t; whereas when the tonnage of the free forging hammer is 3–5 t, the capacity of the operating machine is typically 2–3 t. Suspension grinders are commonly used for grinding and finishing the forgings during the forging process of surface repair and sawing equipment. The surfaces of the forged billets are machined using gantry milling machines or gantry planers, while the surfaces of rod billets are processed with specialized lathes or ordinary lathes; the surfaces of disc billets and ring billets are machined using vertical lathes. Small-sized bars can be cut using hydraulic punching and shearing machines or bow saws; large-sized bars are usually cut with disc saws or grinding wheel saws. Workshop layouts typically use two-span buildings, with the main span used to house forging equipment and its operating machines. The secondary span is used to house auxiliary equipment such as high-pressure pump stations, heating furnaces, and machinery for machining. With this configuration, it is convenient to coordinate the production processes, and smoke exhaust is easy. When auxiliary processes such as cleaning and polishing require a large amount of space, a three-span layout can also be employed. The height of the forging workshop building and the elevation of the crane rails are generally determined based on the space required for maintaining the largest equipment in the workshop. The crane capacity is determined by the weight of the largest component that requires frequent maintenance based on the equipment’s needs. The design of titanium forging workshops involves the use of free forging techniques to process titanium and its alloy ingots into slabs, extruded billets, and finished forged products; it is a design for titanium processing factories’ workshops. The manufacturing process for titanium and its alloys involves forging at high temperatures using

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