Such a powerful forging process is simply unprecedented.

It is worthy of a 50,000-ton hydraulic press. Really good at work.

Although there is no detailed detection data. But Sheng Huainan believes that the quality of these seven spindles is absolutely unquestionable.

Wang Bu'an does have his own uniqueness!

Ordinary automobile crankshafts are all processed and formed as a whole. That is, it is made of a large piece of alloy extrusion and cutting.

However, there is no way to form a super-large marine crankshaft in one go.

No machine can forge a marine crankshaft up to 22 meters in one go.

It has to be connected one by one.

Then high-strength precision welding.

The spindle machining is complete, and it is the turn of the crank arm.

Among the accessories supporting the spindle, the crank arm has the largest area, the largest volume and the largest weight.

The crank arm is the most difficult to machine.

It is difficult to do it with general five-axis CNC linkage machine tools.

The shape of the crank arm is irregular.

Different designs, with different shapes.

Different shapes lead to different properties. So, its design requirements are very high.

At the same time, the crank arm needs to be connected to different spindles. Due to the different directions of force, the strength requirements of the crank arms are very high. Basically, it's about going as high as you can.

Otherwise, the spindle may be fine at full load at high speeds. However, there is a possibility that the crank arm may break.

Overall, there are three basic shapes of crank arms.

Rectangle.

Rotundity.

Oval.

Generally speaking, the rectangular crank arm has the worst material utilization, mass and moment of inertia. But it is convenient to process and manufacture. Direct casting can be done. It is mainly used for low-speed and low-volume crankshafts.

The rounded crank arm structure is relatively simple, which is conducive to crankshaft balancing. It is easy to process and manufacture. Material utilization is inferior to elliptical cranks. It can be manufactured by forging or bar turning. It is suitable for small batch crankshafts, especially multi-support crankshafts.

The oval crank arm has the most reasonable material utilization and high fatigue strength, but for free-forging crankshafts, the crank shape needs to be machined by die. It is mainly formed by strong forging. Casting is not able to provide sufficient strength. Suitable for all forms of crankshafts.

There is no doubt that the application of ultra-large marine spindles is an elliptical structure. The requirements for forging are very high.

As a general rule, the raw material of the crank arm must withstand a twisting force of at least 12 bar or more.

The crank arm after processing and forming needs to withstand a force of more than 10,000 tons as a whole.

If the strength is insufficient, it will crack.

Once there is a crack in the crank arm, it has to be replaced.

To replace the crank arm, the entire crankshaft had to be removed. That's a big problem. I can't move for at least two months.

The weight of a crankshaft is as high as 500 tons, how easy is it to disassemble and install?

In addition, oval-shaped counterweights are also more troublesome.

The size of the counterweights is not the same.

The shape is not the same.

How to counterweight requires precise calculations.

The shape of the counterweight is also irregular. It is also necessary to process a five-axis CNC linkage machine tool.

The question is

The crank arms are big and 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.

And the weight of a counterweight is often more than five tons.

They also have very high strength requirements.

It must be forged repeatedly before it can be formed.

If it is an ordinary five-axis CNC linkage machine tool, it can only be slowly cut and formed. Processed little by little.

A counterweight often takes several days to cut.

Among them, it is possible to change the tool frequently.

After all, the counterweight itself is very strong, and the loss rate of the tool must be very fast.

However, after the crank arm was forged, it was not completed.

On top of each crank arm, there are a lot of accessories. You also have to connect the spindle.

The gears, bearings, hollows, and perforations used on each crank arm are different. The interface for connecting the spindle is also different.

There are also oil-sealed journals, connecting rod journals, oil holes, gear journals, and so on.

The most troublesome thing is the punching. The requirements are very high.

The steel used in the crank arm is inherently very hard. How easy is it to punch holes?

Moreover, if you are not careful when punching, it will affect the strength of the crank arm. If there is a dark injury, it is equivalent to a crippled crank arm. So, it is impossible to use a regular drill bit. Even the hardest drill bits are impossible to punch holes in a crank arm.

So, what means to use?

The only means is lasers.

Ultra-high frequency lasers. Directly pierced the thick crank arm.

Make a small hole first.

Then little by little the cut expands.

However, it is a pity that the 50,000-ton hydraulic press itself does not have a laser drilling device.

Laser perforation, that's a different set.

What to do?

Simple.

Five-axis CNC machine tools come with powerful lasers.

The laser of the machine tool is mainly used for cutting and surface dressing. However, after adjusting the parameters, it can also be used to punch holes.

"Is it really possible?" Pang Xihua was a little troubled.

"Yes. Wang Buan replied affirmatively.

Suspicious of Cybertron's technology?

There is no need.

No, the crank arm correction is in place.

The five-axis CNC linkage machine began to simulate drilling. Determine the location of the punch and the frequency of the laser.

All of this is done by computer simulation.

It simulates the operation of the crank arm after the hole is drilled and identifies any problems.

Repeated simulations.

Repeated revisions.

Until it is determined that there are no major defects.

At this point, it's up to the technician to decide. If you think it's okay, then you really start punching.

Once you start punching, there's no chance of backtracking.

Are you sure.

Determined for the second time.

Suddenly, a huge pillar of light shot out.

The crank arm, which is more than 5 centimeters thick, silently appears with a large hole.

But the laser beam has been easily penetrated.

"Ah!" Pang Xihua couldn't help but exclaim.

"So fast?" the other technicians were 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 with a pillar of light with a diameter of more than 2 centimeters.

In other words, how much power is this laser emitter?

How much energy does a pillar of light over 2 centimeters in diameter have to consume?

If it's powered by electricity, how much power does it need? How much voltage do you need?

If it's used to make laser cannons, wouldn't it?

It's just a pity that everything is not answered.

Wang Buan felt that there was no need for him 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 emitter is, it has nothing to do with other people. For technicians, it is also not necessary to know.

Connector

"It's not easy."

A technician named Xie Liangzhe whispered to himself. was quite worried about Wang Buan.

The power of the laser is so ferocious, in fact, it is not good.

That is, the spindle interface is prone to errors.

The interface between the spindle and the crank arm is not penetrated.

The spindle only needs to be inserted half the depth of the crank arm. It is enough to be able to do the overall movement with the crank arm.

If the interface is penetrated, it does not meet the requirements.

This necessitates adjusting the working depth of the laser.

Only 25 cm deep can be dissolved.

If it goes beyond this depth, it is tantamount to failure.

Wang Buan began to adjust the parameters.

The massive pillar of light erupted again.

On the surface of the crank arm, a large hole is recessed.

The depth of the big hole is exactly 25 centimeters. It is octagonal. It just matches the two ends of the spindle.

While punching holes in the crank arms, the five-axis CNC machine began machining gears and bearings.

It has a large number of auxiliary workbenches, which can work more than a dozen parts at the same time. Regardless of size and thickness.

There is no difficulty in machining gears.

The machining of bearings is a bit complicated.

The bearings are matched. It must be machined one by one.

The first thing to be processed is the balls.

The heavy cemented carbide is sent to the auxiliary table of the hydraulic press.

Start squeezing.

The alloy is directly extruded into a round ball.

The original large piece of cemented carbide was pressed into the size of a volleyball.

Some of the cemented carbide is only the size of a ball.

"Oh my God, such a strong work ability!" Pang Xihua felt his eyes straighten.

What kind of processing is this?

How much hydraulic capacity is that?

Could it be that it is really 50,000 tons?

Otherwise, how is it possible to press cemented carbide to the size of a palm?

A small ball feels like it weighs hundreds of pounds. Terrifying to this level, it's simply unheard of. Don't say you've seen it.

After the ball is machined, it is the groove of the bearing, and then the jacket.

Then there are the camshafts

Then there are the fasteners

Fasteners include many. Including self-tapping screws, anti-loosening screws, hexagon socket screws, and more.

The specifications of each screw are different. Different gears and different bearings require screws with different specifications.

The biggest requirement of these screws is that the force is also very strong. A force of more than 10,000 tons is required for a single screw. It is conceivable how high their quality requirements are.

Previously, the screws used by North 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 mean that it is produced just for production.

It requires adjusting the production line.

It needs to be equipped with the corresponding hydraulic press.

It is also necessary to support a large number of extrusion, cutting, quenching and forging machinery.

Each ball is made after thousands of processes. The price of a Corolla sedan seems to be understandable.

However, here in Wang Buan, everything is so simple and rude.

Extrusion.

Direct extrusion.

Transformers are so crude and direct.

Directly extrude a large piece of heavy hard alloy into a ball with the required specifications.

Over there, the laser continues to punch holes.

This time, it's about punching out the oil holes.

Crankshafts require a lot of lubricating oil. There must be an oil transfer hole.

The oil transfer hole must be inclined at a certain angle.

Obviously, the difficulty of this work is also very high.

When machining with a drill bit, you need to take into account the problem of chip evacuation. The metal dust must be cleaned out!

If there is powder residue in the oil hole, it will affect the lubrication effect.

Ordinary automobile crankshafts are all processed by drills.

However, here in Wang Buan, it is directly trouble-free.

Or lasers.

Resize.

Adjust the wavelength.

Adjust the angle.

A thin pillar of light dissolved the oil hole.

A high-intensity laser that melts the metal directly.

"I want it!"

"I want it!"

Pang Xihua finally blurted out.

He deeply believed that Wang Buan did not lie.

What he is currently showing is indeed a 50,000-ton hydraulic press.

Only 50,000 tons of terrifying working capacity can squeeze the alloy into such a small ball. An 80,000-ton hydraulic press can't do it.

"The price is very cheap. It's just 100 million. Wang Buan said.

"Okay. Pang Xihua readily agreed.

The 50,000-ton hydraulic press was only sold for 100 million, and he definitely earned it.

Do you know how much money was spent on the 50,000-ton hydraulic press built by the North Heavy Industry itself? More than 1 billion? The performance is not as advanced as that provided by Wang Buan.

Others sell a hydraulic press and give away a high-tech five-axis CNC machining center.

The capabilities of this machining center are also extremely strong. Accuracy reaches 1 micron.

Due to the special purpose of marine crankshafts, the requirements for machining accuracy are also very high. It cannot be lower than 5 microns.

What is 5 microns? It's basically a fraction of a human hair.

The accuracy requirements of marine crankshafts are so demanding.

Ships and other aircraft.

machine isoaxis.

For Pang Xihua, this sentence was extremely impressive.

What does this mean?

This means that shipyards must determine the supply of diesel engines before they dare to take shipbuilding orders.

If you can't get a diesel engine, you can only watch the order float by in vain. Otherwise, it would be a tragedy if the hull was built, but there was no matching diesel engine.

Why is the diesel engine not in place?

Because there are not enough crankshafts.

Twenty years ago, there were only three companies in the world capable of producing very large crankshafts.

At the moment, the number is basically the same.

Wärtsilä.

General Electric.

Mitsubishi Heavy Industries.

There is no more fourth.

The crankshaft used by n is also machined by someone else.

Huge ships of more than 10,000 tons and large crankshafts require long delivery times.

However, if it is equipped with the 50,000-ton hydraulic press sold by Wang Bu'an, as well as a five-axis CNC machine tool, I feel that I can produce a super-large crankshaft in one day. The quality is also bargaining.

Xie Liangzhe couldn't help but say: "Chief Engineer Wang, since the efficiency of your industrial park is so high, why don't you produce it directly for us?"

Wang Buan shook his head and said, "No." Mass production is up to you. ”

He stood by his principles.

The industrial park produces only raw materials.

When necessary, it can show you the manufacturing process of the sample to enhance your confidence.

However, for mass production, it must be arranged separately.

Xie Liangzhe regretfully stopped talking.

Pang Xihua also felt a little regretful. Then I was refreshed.

Wang Bu'an has already demonstrated it to them.

A 50,000-ton hydraulic press is strong.

The five-axis CNC linkage machine tool is also of high quality.

If Wang Buan can use them to produce crankshafts quickly, why can't they?

They can't let Wang Buan underestimate him!

Today's second update. Ask for a little vote, thank you.

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