ã€China Aluminum Industry Network】 1. Project Overview 1. Aluminum and aluminum alloy forging production line 2. Main products: Free forgings and die forgings of all aluminum alloys (including some titanium alloys and high-temperature alloys) 3. Production scale: 15000T/year (including 12000T/year aluminum alloy forgings, and other titanium alloys and high-temperature alloy forgings)
4. Construction investment amount: RMB 150 million 2. Reasons (purpose and significance) and main contents (tasks and targets) for project establishment
1. Purpose of Project Establishment Forging production is one of the main ways to provide mechanical parts blanks to various industrial sectors. The advantage of forging production is that it can not only obtain the shape of mechanical parts, but also improve the internal structure of the material and improve the mechanical properties. In general, most of the important mechanical parts with high mechanical and mechanical requirements are manufactured by forging.
The weight of the forgings at the top of the aircraft accounts for 80%, the weight at the top of the tanks accounts for 70%, and the weight of the forgings in the car accounts for 60%. The turbine shaft, turbine impeller, rotor and guard ring in the power industry are all forged. From these examples, it can be seen that forging production plays an extremely important role in the industrial industry.
Aluminum alloy has been used in various industrial sectors because of its small specific gravity, specific strength, and high specific rigidity. Aluminum alloy forgings have become an indispensable material for mechanical parts in various industrial sectors. All kinds of forgings that can be forged with mild steel can be forged from aluminum alloys. Aluminum alloys can be forged on various forging equipment such as forging hammers, mechanical presses, hydraulic presses, head forging machines, and hole expanding machines, and can be forged, forged, upset, roll forged, and bored. In general, aluminum forgings with small size, simple shape, and laxity requirements can be easily forged on the forging hammer. However, for aluminum forgings with large specifications and severe deformation, water (liquid) pressure should be selected. Machine to forge. Aluminum forgings with large and complex overall structures are not produced by large-scale die forging hydraulic presses. Especially in the past decade, with the advancement of science and technology and the development of the national economy, higher and higher requirements have been put forward for materials, forcing aluminum alloy forgings to develop toward large-scale integration, high strength, high toughness, and sophisticated precision. Greatly promoted the development of large and medium-sized hydraulic presses.
With the development of China's transportation industry towards modernization and high speed, the lightweight requirements for transportation tools have become increasingly strong. The demand for aluminum-based steel has grown louder and louder. In particular, important weight components and structural parts of airplanes, spacecrafts, railway vehicles, underground railways, high-speed trains, freight cars, automobiles, ships, ships, artillery, tanks, and mechanical equipment, which require high lightness, have been in recent years Use of aluminum and aluminum alloy forgings to replace the original steel structural components, such as aircraft structural parts are almost all aluminum die forging; automotive (especially heavy-duty vehicles and large and medium-sized passenger cars) wheels, bumper, base frame beam; tank floating wheel , Cannon frame; Helicopter's moving ring and immovable ring; Train's cylinder and piston skirt; Woodworking machinery fuselage; Textile machinery base, track and stranding plate, etc. are applied to the manufacture of aluminum alloy die forgings. Moreover, this trend is growing dramatically, and even some aluminum alloy castings have begun to use aluminum alloy die forgings instead.
At present, there are few large-scale forging hydraulic presses in the world, and China is very few. Along with the modernization of the national defense industry and the development of the civil industry, especially the transportation industry, the type and output of aluminum alloy die forged parts can not only meet the needs of the domestic market. Needs, the international market also has a big gap. Therefore, it is very necessary and timely for us to step up the construction of several large and medium-sized aluminum alloy forging production lines. It has great practical significance and long-term significance for the rapid development of the national economy and the modernization of the defense industry.
2. Main Tasks and Contents of the Project The main tasks of the project are: based on China's current national conditions and strengths, and with the help of international advanced technology, on the basis of extensive research, alloys, status, types and specifications of aluminum alloy forgings and die forgings , performance and use, as well as production process and key technologies for analysis and selection, configuration of reasonable and economical and practical host and auxiliary equipment and water, wind, electricity, gas and other ancillary facilities, construction of the plant and installation, commissioning equipment, later produced a country Urgently needed, qualified domestic and foreign markets for large and medium-sized aluminum alloy forgings and die forgings. Due consideration will be given to the production of titanium alloys, superalloys, and steel forgings.
The goal of the project is to build a modern production line for forgings and die forgings of large and medium-sized aluminum alloys (including some titanium alloys and steel materials) with an annual output of 15,000 T/a, and to provide large quantities of qualified new materials for the defense industry and the national economy. Meet the needs of domestic and foreign markets.
Third, the characteristics of aluminum alloy forgings, application range and market analysis 1, the characteristics of aluminum alloy forgings 1) The density is small, steel forgings 34%, 30% of copper forgings, is an ideal lightweight material;
2) It has higher specific strength, higher specific stiffness, higher specific elastic modulus and higher fatigue strength. It is suitable for key components with high requirements for light weight, and its comprehensive performance is much higher than other materials.
3) The internal organization is fine, uniform and flawless, and its reliability is much higher than that of aluminum alloy castings and die castings, and it is also higher than other material forgings.
4) The aluminum alloy has good plasticity and can be processed into various high-precision forgings with complicated shapes. The machining allowance is small, which is only about 20% of the aluminum alloy tensile plate processing volume, which greatly saves man-hours and costs.
5) Aluminum forgings have good corrosion resistance, thermal conductivity and non-magnetic properties, which are unmatched by steel forgings.
6) The surface is smooth, beautiful, with good surface treatment performance, beautiful and durable.
It can be seen that the aluminum forgings have a series of excellent features and provide good conditions for aluminum forgings to replace steel, copper, magnesium, wood and plastics.
2. Application Fields of Aluminum Alloy Forgings In recent years, due to the decrease in the cost of aluminum materials, the improvement of performance, and the widening of specifications, their application fields have been increasing. Mainly used in aerospace and aviation, transportation, automotive, shipbuilding, energy and power, electronic communications, petrochemicals, metallurgical mining, machinery and electrical appliances and other fields. The characteristics and uses of the main forged aluminum alloy are shown in Table 1.
Table 1 Characteristics and Uses of Wrought Aluminum Alloys
Note: A-excellent; B-good; C-general; D-poor 3. Market analysis 1) Analysis of production and sales of aluminum alloy forgings Aluminum and alloy forgings have a series of advantages above, in aerospace, automobiles, and ships. Industries such as transportation, weapons, and telecommunications are favored and their applications are becoming more widespread. According to preliminary statistics, aluminum forgings have increased from 0.5% in 1985 to around 15% in 2002 in the world's total forging production. At present, the world consumes about 3.44 million tons of forgings, of which aluminum forgings account for about 500,000 tons. Titanium forgings and high-temperature forgings account for about 0.5%, or about 18,000 t/a, and steel and iron forgings still account for the vast majority. From the aluminum processing industry's point of view, the current global aluminum production (including recycled aluminum) is more than 30 million t/a, of which 80% is to be converted into processed materials, that is, the current annual output of processed aluminum in the world is 24 million t/year. Around a, about 57% of plates, belts, and foils are used, and extruded materials account for about 38%. Aluminum alloy forging materials are difficult to use because of their high cost and production technology. They have been used only in particularly important stress areas. In the past decade or so, due to the needs of modernization and lightening of military and civil industries, especially transportation industry, The demand for aluminum replacement steel is very urgent, and therefore aluminum forgings and applications have been rapidly growing. The proportion of aluminum has increased from 0.5% in 1985 to 2.1% in 2002, which is about 500,000 t/a.
In order to meet the increasing demands of military and civil departments for aluminum and aluminum alloy forgings, countries around the world are focusing on human, material and financial resources to develop aluminum forging production, designing and manufacturing various forging and stamping equipment, especially large and medium-sized water (liquid) pressure. forging machine. However, due to the relatively expensive forging equipment, long manufacturing cycle, and forging production technology, it is difficult to meet market needs. At present, the aluminum forgings production capacity in the world is about 300,000 t/a, which cannot meet the demand for consumption of 500,000 t/a. Due to the large and medium-sized water (liquid) pressure forging equipment and low production capacity in China, it is far from meeting the demand of the industrial sector for aluminum forging parts. The annual gap is above 15,000 t/a. By 2010, the annual consumption of aluminum forgings may reach more than 50,000 t/a due to the large increase in automobiles, aircraft, and ships in China.
2) Market Analysis From the above analysis, aluminum and aluminum alloy forgings are mainly used in industrial sectors requiring a large degree of lightness. According to the current situation in various countries, the main market distribution is exemplified as follows.
1 Aviation (aircraft) forgings: Forgings on aircraft account for more than 80% of the weight of aircraft materials, such as landing gear, frames, ribs, engine rings, moving rings, and so on. Thousands of forgings are used in an aircraft, including A few high-temperature parts are made of high-temperature alloys and titanium alloy forgings. Most of them have been aluminized. For example, the United States, Bo Ying Oh, your company, has an annual output of 1,000 aircraft, and it needs to consume tens of thousands of tons of aluminum alloy forgings each year. The military aircraft and civilian aircraft such as fighter planes developed in China are also rapidly developing, and aluminum forgings to be consumed will also increase year by year.
2 Aerospace forgings: Forgings on spacecraft are mainly forging rings, rims, wing spars and machine bases. Most of them are aluminum forgings and only a few titanium forgings. The development of spacecraft, rockets, missiles, and satellites is increasing the demand for aluminum forgings. For example, in recent years, the AI-Li alloy shell forgings for ultra-long-range missiles developed in China each weigh more than 300 kilograms worth hundreds of thousands of yuan.
3 Ordnance Industry: The number of aluminum alloy forgings as bearing parts has greatly increased in conventional weapons such as tanks, armored vehicles, personnel carriers, combat vehicles, rockets, artillery, and warships, and basically replaced steel forgings.
4 Automobiles are more promising industries that use aluminum alloy forgings, and they are also large users of aluminum forgings. Mainly used as hubs (especially for heavy-duty vehicles and large and medium-sized passenger cars), bumpers, base frames and other small and medium-sized aluminum forgings, among which aluminum hubs are used in large amounts for aluminum forgings and are mainly used for buses, trucks and heavy-duty vehicles. on. In recent years, applications have also started in small and medium-sized cars, motorcycles and limousines. According to statistics, the annual growth rate of aluminum wheel usage in the world has reached more than 20% in recent years, and the current usage has reached more than 100 million. China has just started, but FAW, Second Automobile and other large auto companies are beginning to research and development. With the increase in vehicle output (in 2005 China's auto production is expected to reach 6 million vehicles/year, the world's auto production may exceed 80 million vehicles/year), and the use of aluminum wheels and other aluminum forgings will be surprisingly developed.
5 In the energy and power industry, aluminum forgings will gradually replace some steel forgings to make racks, retaining rings, moving rings and immobile rings, as well as coal mining transport wheels and LNG flanges. Generally, they are large and medium-sized forgings.
6 A large number of aluminum forgings are used on ships and vessels as racks, moving rings, immovable rings, and gun racks.
7In the machinery manufacturing industry, it is mainly used for woodworking machinery, textile machinery, etc., as racks, sliders, connecting rods, and crossovers, etc.. Only the stranded aluminum forgings for textile machines require tens of thousands of pieces each year in China. , weighing more than 1,000 tons.
8 The mold industry uses aluminum alloy die forgings to make rubber molds, shoe molds, and other light-duty molds. The annual dosage is 10,000 tons.
IV. Development of forging production 1. Foreign development status and horizontal forging production is a very old industry, but the mass production of aluminum alloy forgings began in the 1950s. After decades of modernization, no matter in terms of industrial equipment, mold design and manufacturing, production technology and technology, or in the variety of products, production scale and quality, etc. have been rapid development, especially the United States, Russia, The development level of forging production in Germany, Japan, France, Italy, the Czech Republic, Austria, Switzerland and other countries has reached a very high level. At present, the world has hundreds of forging plants and thousands of forging presses. The annual output of forgings is nearly 5 million t/a, among which aluminum alloy die forgings are about 300,000 t/a (the annual consumption is nearly 500,000 t/a). There are more than 500 large and small water (liquid) forging presses in the world, of which more than 40 large-scale water (liquid) forging presses with a capacity of more than 100 MN and about 20 medium-sized (liquid) pressure forging presses with a capacity of 300 MN or more. The distribution of heavy-duty forging presses above 300MN is: Russia 4, one of which is 750 MN, which is a comparison in the world; the United States 5, including 2 450 MN; France 1 650 MN; Germany 2; China 1 Taiwan; Romania 1; England 1 and so on. The main features of these forging water (liquid) presses are compact structure, multi-function, high degree of automation, equipped with a manipulator, quick mold changing device, plane configuration machine, which are conducive to continuous operation and high production efficiency. In addition, with the increase in the size of aluminum alloy die forgings and the improvement in precision, large-scale precision multi-directional die forging presses have received increasing attention. Each country has a number of large-scale multi-directional die hydraulic presses, among which three are from the United States and the largest is 300 MN; France 1 Taiwan is 650 MN; in the United Kingdom, one is 300 MN; in China, one is 100 MN; in Russia, two are 200 MN and 500 MN; in Germany, one is 350 MN. Multi-directional die forging press belongs to precision forging equipment. It is equipped with PLC system and computer control system. It can automatically adjust the energy, stroke, pressure, and speed, control the key parts better working point, monitor and display the working status. The system predicts and protects system failures, equipment overloads, over-temperature and out-of-control, and controls product quality. Some also include offset detection, synchronization system, workbench and rack deformation compensation, magnetic packet memory, integrated circuit, optical fiber communication, color screen, etc., which can realize automatic control and science of the whole machine or entire train, or even the entire workshop. management.
In the aluminum and aluminum alloy forging technology developed a large number of new forging processes, new technologies, such as liquid die forging, isothermal forging, powder forging, multi-directional die forging, precision dieless forging, partial die forging, wrapping Die forging plays an important role in simplifying processes, reducing processes, saving energy, expanding quality, increasing specifications, improving quality and production efficiency, protecting the environment, reducing labor intensity, and improving economic efficiency. Dedicated computer software provides reliable guarantees for controlling major process parameters such as forging temperature, forging pressure, degree of deformation (under-pressure), and process lubrication, as well as controlling product dimensions, internal organization, and mechanical properties.
The design and manufacture of forging dies is the key to the aluminum alloy forging technology. The CAD/CAM system of forgings has become very mature and popular. In the United States, CAD/CAM systems are being replaced by CIM (computer integration). CIM includes complete sets of technologies, computer technologies, CAD/CAM technologies, robots, expert systems, processing plans, control systems, and automatic material handling, providing conditions for optimized design and process improvement of die forgings. For example, in the automotive industry, the design and process optimization of front beam, claw, hub, crankshaft and other parts can reduce the weight of the optimized design of the horns by 15%, reduce the weight of the wheels by 30%, and reduce the crankshaft weight by 20%. Improve production efficiency and reduce energy consumption.
Breakthrough progress has been made in product variety and quality. At present, forged aluminum alloys developed and developed in the world have hundreds of states and dozens of states. Mass production of different alloys, different states, different properties, different functions, and various Aluminum alloy forgings of various shapes, various specifications, and various uses have more than ten large-scale enterprises with a scale of more than 30,000 t/a. At present, the large projected area of ​​aluminum alloy die forgings that can be produced in the world reaches 5M2 (750MN), the longer aluminum forgings can reach 15M, the heavier aluminum forgings can reach 1.5t, and the larger forging rings can reach 7.5M in diameter. It can meet the needs of larger aircrafts, spacecrafts, rockets, missiles, satellites, ships, aircraft carriers, and power generation equipment and lifting equipment. The internal organization, mechanical properties and dimensional accuracy of the product can also meet the requirements of various users, achieving a very high level of product development.
In recent years, all countries in the world have had little efforts in the construction and reconstruction of large and medium-sized forging hydraulic presses. Therefore, in general, the production of aluminum alloy forgings in the world cannot meet the demand for aluminum forgings due to the light weight of transportation, and it is necessary to build new aluminum forgings. Several modern large and medium aluminum forging production lines.
Foreign countries have made great progress in the production of titanium forgings and high-temperature forgings, and they have achieved a very high level.
2. Domestic development status and level analysis Forging production has a long history in China. In the early period of Yin Ruins culture more than 3300 years ago, forging has been used for weapons production. Before liberation, forging production was very backward. After liberation, the forging and press production developed rapidly. The free-forging hydraulic press below 125 MN, the forging hydraulic press below 300 MN, the die forging hammer below 160 KN, the friction press below 1600 KN, and the hot die forging press below 80000 KN have been equipped in various series. Forging plant. In China, there are only 300 MN, 100 MN, 60 MN, 50 MN, and 30 MN five large and medium-sized aluminum forging water (liquid) presses and one 100 MN multi-directional molding hydraulic press. The annual production capacity is only about 10,000 t/a, and the larger die forgings projected area is 2 M2. (Aluminum alloy), 1.2M2 (titanium alloy), Larger length 7M, Larger width 3.5M, Larger diameter φ3.5M for forging rings, and Aluminum alloy bobbin with disc diameter φ534-φ730mm. The product variety is relatively small. For example, forgings in industrialized countries already account for about 80% of all forgings, while China only accounts for about 26%. Forging die design abroad, mold manufacturing has long been the introduction of computer technology, forging die CAD and forging process simulation has entered the practical stage, and many of our forging plant in this area has just started. The level of automation and technological level of technological equipment is also relatively backward.
Based on the above analysis, we can see that the current aluminum alloy forging industry in China in terms of process equipment; mold design and manufacturing; production technology and new technology, new material development; or product variety and specifications; product output and scale; Production efficiency and mass production; product quality and efficiency and other aspects have a wide gap with foreign advanced level. Not only can not meet the growing demand for aluminum alloy forgings in the domestic and foreign markets, but also can not keep up with the lightweight of transportation (such as aircraft, automobiles, high-speed trains, ships, etc.) to replace the steel forgings with aluminum forgings. To this end, China should concentrate its human, material, and financial resources to improve the level of aluminum alloy forging production process equipment and production technology as soon as possible, and as soon as possible to build a number of 60 ~ 500MN modern aluminum alloy forging and hydraulic press production lines to reduce foreign advanced as soon as possible The gap in level meets the needs of domestic and foreign markets.
V. Basic conditions and favorable conditions of the construction unit VI. Typical product and production scale 7. Analysis of production process and main technical processes 8. Major equipment and auxiliary equipment and supporting facilities 9. Funds estimation and source 10. Economic and technical analysis 11. , safety and environmental protection 12, plane distribution Note: Detailed discussion of the five to twelve chapters should be written in the feasibility analysis report.
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