美國Phoenix 鋼鐵公司無縫鋼管廠采用Calmes軋管工藝，其軋管機組的平面布置圖是由意大利 Albert Calmes博士設計的，Phoenix 鋼鐵公司設計科在其他工程公司的配合下完成詳細設計，為了生產各種鋼號的優質無縫鋼管，使其內外徑和壁厚均具有良好的公差，軋管機組的設計以下列三方面內容為核心：Calmes在水壓沖孔機方面的專利、Calmes關于改進曼內斯曼延伸機方面的專利以及他所提出的周期軋管機的軋輥孔型。
這一軋管機組采用(yong)Phoenix 鋼(gang)鐵公司(si)平爐頂鑄生產的最大重量達8000磅的波浪(lang)形鋼(gang)錠為原料，成品管直徑為51/2~16英寸壁厚(hou)為1/4~3英寸。
這種軋(ya)管機組的一(yi)(yi)大特點(dian)是直接采用(yong)平爐鋼(gang)(gang)錠(ding)在一(yi)(yi)個(ge)連續的工(gong)藝(yi)過(guo)程(cheng)中軋(ya)制成管，并且僅一(yi)(yi)次(ci)加(jia)(jia)熱就(jiu)能完成沖(chong)孔(kong)、延(yan)伸，周(zhou)(zhou)期軋(ya)管各工(gong)藝(yi)過(guo)程(cheng)，其主要工(gong)藝(yi)過(guo)程(cheng)是：鋼(gang)(gang)錠(ding)清理、加(jia)(jia)熱、沖(chong)孔(kong)、延(yan)伸、周(zhou)(zhou)期軋(ya)管，再加(jia)(jia)熱、定徑、修磨(mo)，精整和水壓試(shi)驗，以下主要論述(shu)沖(chong)孔(kong)、延(yan)伸和周(zhou)(zhou)期軋(ya)管等三個(ge)工(gong)藝(yi)過(guo)程(cheng)。
1. 水壓(ya)沖孔
鋼(gang)錠(ding)(ding)經火焰燒剝去除(chu)表面缺陷后，在車底式加熱(re)爐內(nei)加熱(re)到2340~2370℉。用小車運送到沖(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)機(ji)上(shang)進行沖(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)操作(zuo)。鋼(gang)錠(ding)(ding)在1200t水壓沖(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)機(ji)上(shang)沖(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)，其(qi)操作(zuo)過(guo)程(cheng)如下(xia)：用水壓操縱的(de)(de)裝料機(ji)將(jiang)(jiang)鋼(gang)錠(ding)(ding)送人沖(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)機(ji)，將(jiang)(jiang)其(qi)置(zhi)(zhi)于支(zhi)架(jia)上(shang)的(de)(de)沖(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)位置(zhi)(zhi)，兩個支(zhi)架(jia)中有一個是固定(ding)在沖(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)模(mo)上(shang)的(de)(de)，而另一個則可(ke)以(yi)伸縮(suo)，沖(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)模(mo)前移(yi)時即將(jiang)(jiang)鋼(gang)錠(ding)(ding)套住，開始沖(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)操作(zuo)。鋼(gang)錠(ding)(ding)沖(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)后，其(qi)形狀(zhuang)(zhuang)像杯(bei)子，被(bei)稱為杯(bei)狀(zhuang)(zhuang)體(ti)，沖(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)模(mo)的(de)(de)內(nei)徑決定(ding)杯(bei)狀(zhuang)(zhuang)體(ti)的(de)(de)外徑。沖(chong)(chong)(chong)(chong)(chong)頭直徑則確定(ding)杯(bei)狀(zhuang)(zhuang)體(ti)內(nei)孔(kong)(kong)(kong)(kong)(kong)的(de)(de)直徑，圖(tu)13-1所示(shi)是沖(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)模(mo)前移(yi)但尚(shang)未套上(shang)鋼(gang)錠(ding)(ding)前端時的(de)(de)狀(zhuang)(zhuang)況，沖(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)模(mo)前移(yi)達到其(qi)沖(chong)(chong)(chong)(chong)(chong)程(cheng)的(de)(de)75%,可(ke)伸縮(suo)支(zhi)架(jia)從下(xia)部移(yi)出，圖(tu)13-2示(shi)出鋼(gang)錠(ding)(ding)已被(bei)套入沖(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)(kong)模(mo)內(nei)。
圖(tu)13-3示出整個杯(bei)狀體還套在沖孔(kong)模內的(de)情況，從圖(tu)13-3可以看出被沖孔(kong)的(de)鋼(gang)(gang)錠(ding)前端只(zhi)剩下很薄的(de)杯(bei)底。鋼(gang)(gang)錠(ding)呈方形(xing)或圓形(xing)，即直徑為13英(ying)(ying)寸(cun)，16英(ying)(ying)寸(cun)，19英(ying)(ying)寸(cun)和(he)21英(ying)(ying)寸(cun)的(de)波浪形(xing)圓錠(ding)。
2. 杯狀體延伸
在(zai)(zai)(zai)延伸(shen)(shen)機(ji)上(shang)(shang)，杯(bei)狀體在(zai)(zai)(zai)兩個(ge)在(zai)(zai)(zai)水平(ping)面(mian)上(shang)(shang)成(cheng)反向傾斜的斜置軋輥(gun)間，通過(guo)具有(you)一定(ding)(ding)形(xing)(xing)狀的頂頭進行軋制。在(zai)(zai)(zai)垂直平(ping)面(mian)上(shang)(shang)有(you)兩個(ge)固定(ding)(ding)導板，其(qi)作用是限制變形(xing)(xing)區的杯(bei)狀體的斷面(mian)形(xing)(xing)狀使之(zhi)不至于過(guo)分橢圓。這種延伸(shen)(shen)機(ji)與曼(man)內斯(si)曼(man)斜軋穿孔機(ji)很相似，它可以延伸(shen)(shen)杯(bei)狀體，并穿透杯(bei)底(di)使之(zhi)成(cheng)為(wei)空心坯。
圖13-4示出采用曼(man)內斯曼(man)輥型的(de)延(yan)(yan)伸機對杯(bei)狀體進行延(yan)(yan)伸的(de)過程。圖13-5所示是(shi)采用了Calmes軋輥的(de)情況，空心坯(pi)延(yan)(yan)伸時，最好選用延(yan)(yan)伸率(lv) λ＝1.75,最大不超過2。
延(yan)伸機(ji)采用3相、60Hz、功率為2208kW(3000馬力）的(de)同步電機(ji)傳動，額定電壓、轉速(su)分別(bie)為6900V,1500r/min,減速(su)機(ji)的(de)速(su)比為3。
延伸機的(de)主要(yao)特點之(zhi)一(yi)是它所生產的(de)空心坯壁厚比較均勻。斜軋(ya)延伸機的(de)延伸過程可參看圖13-6。
杯狀體離開軋輥(gun)成為空(kong)心(xin)坯后(hou)，用以夾持(chi)頂桿(gan)的鎖門就(jiu)打(da)開，空(kong)心(xin)坯從延伸機輸出，用橫移小(xiao)車將其運送到周期軋管機。
3. 周期軋(ya)管機軋(ya)管
周期軋(ya)(ya)(ya)管機(ji)(ji)由一臺額定功(gong)率(lv)為(wei)1472kW(2000馬力）的(de)(de)(de)電動(dong)(dong)機(ji)(ji)傳動(dong)(dong)，該電動(dong)(dong)機(ji)(ji)的(de)(de)(de)功(gong)率(lv)能(neng)達2208kW(3000馬力）而不至于(yu)過分發熱。電動(dong)(dong)機(ji)(ji)軸上(shang)配有飛輪(lun)，在每一轉中(zhong)它既提供(gong)能(neng)量(liang)(liang)又(you)獲得能(neng)量(liang)(liang)，軋(ya)(ya)(ya)機(ji)(ji)速(su)(su)(su)度是(shi)(shi)30~105r/min,較(jiao)低的(de)(de)(de)速(su)(su)(su)度用(yong)于(yu)軋(ya)(ya)(ya)制(zhi)大管，而較(jiao)高的(de)(de)(de)速(su)(su)(su)度用(yong)來軋(ya)(ya)(ya)小管。操(cao)作(zuo)(zuo)喂(wei)(wei)料器的(de)(de)(de)高壓(ya)水(shui)壓(ya)力為(wei)2800 Ibl/in或1500 Ibf/in,以向一個前進(jin)缸(gang)和兩(liang)個回程(cheng)缸(gang)供(gong)水(shui)，正常運轉時(shi)(shi)，向前進(jin)缸(gang)連續地供(gong)高壓(ya)水(shui)，向前喂(wei)(wei)料時(shi)(shi)，高壓(ya)水(shui)由回程(cheng)缸(gang)流出(chu)，因此向前喂(wei)(wei)料的(de)(de)(de)速(su)(su)(su)度受到從回程(cheng)缸(gang)排(pai)出(chu)的(de)(de)(de)高壓(ya)水(shui)量(liang)(liang)的(de)(de)(de)控(kong)制(zhi)。這一操(cao)作(zuo)(zuo)在咬(yao)(yao)人時(shi)(shi)是(shi)(shi)手工操(cao)作(zuo)(zuo)，由操(cao)作(zuo)(zuo)工自行控(kong)制(zhi)，軋(ya)(ya)(ya)制(zhi)時(shi)(shi)則是(shi)(shi)自動(dong)(dong)操(cao)作(zuo)(zuo)的(de)(de)(de)，操(cao)作(zuo)(zuo)工應使喂(wei)(wei)料器的(de)(de)(de)前進(jin)速(su)(su)(su)度與軋(ya)(ya)(ya)輥的(de)(de)(de)速(su)(su)(su)度同(tong)步；此外，操(cao)作(zuo)(zuo)工還必須控(kong)制(zhi)空(kong)氣(qi)壓(ya)力p1,空(kong)心坯咬(yao)(yao)人時(shi)(shi)，迅速(su)(su)(su)把(ba)空(kong)氣(qi)從缸(gang)里排(pai)出(chu)，開始(shi)軋(ya)(ya)(ya)制(zhi)后，根據所(suo)軋(ya)(ya)(ya)管子(zi)的(de)(de)(de)規格(ge)調整空(kong)氣(qi)壓(ya)力P1.液(ye)壓(ya)自動(dong)(dong)喂(wei)(wei)料器斷面(mian)示(shi)(shi)意(yi)圖如圖13-7所(suo)示(shi)(shi)。
該(gai)喂料(liao)(liao)器(qi)的(de)(de)一個特點(dian)是(shi)，空氣缸的(de)(de)沖(chong)(chong)(chong)程長(chang)度(du)都保持不(bu)變。軋(ya)(ya)制152~203mm管(guan)子(zi)(zi)時(shi)沖(chong)(chong)(chong)程長(chang)度(du)為762mm,而軋(ya)(ya)制228~406mm的(de)(de)管(guan)子(zi)(zi)時(shi)，則沖(chong)(chong)(chong)程長(chang)度(du)為838mm.這意(yi)味著軋(ya)(ya)輥(gun)工作段(duan)長(chang)度(du)是(shi)恒定不(bu)變的(de)(de)，在(zai)(zai)軋(ya)(ya)輥(gun)車床上凸輪的(de)(de)安裝位(wei)置恰可使軋(ya)(ya)輥(gun)的(de)(de)工作段(duan)和所(suo)對(dui)應的(de)(de)喂料(liao)(liao)器(qi)一致(zhi)。喂料(liao)(liao)的(de)(de)方向與(yu)軋(ya)(ya)輥(gun)旋轉的(de)(de)方向是(shi)相反的(de)(de)，軋(ya)(ya)機(ji)操作工控(kong)制喂料(liao)(liao)速度(du)并將此速度(du)和軋(ya)(ya)輥(gun)轉速保持同步。芯(xin)(xin)棒長(chang)度(du)為4572~4877mm,同時(shi)使用(yong)的(de)(de)芯(xin)(xin)棒為5根，其中一根芯(xin)(xin)棒用(yong)于軋(ya)(ya)制，其余芯(xin)(xin)棒在(zai)(zai)空氣中冷卻，然(ran)后浸人水中進一步冷卻，一般是(shi)3根芯(xin)(xin)棒在(zai)(zai)空氣中冷卻，一根芯(xin)(xin)棒在(zai)(zai)水里冷卻，軋(ya)(ya)機(ji)運(yun)行(xing)中5根芯(xin)(xin)棒就這樣(yang)反復(fu)循(xun)環著。
根據所軋(ya)管子(zi)規格調下(xia)輥高度，調整后其(qi)(qi)高度是不變(bian)的(de)(de)(de)。當空(kong)心坯(pi)被(bei)軋(ya)成帶有(you)皮爾格頭的(de)(de)(de)管子(zi)后，應將上(shang)輥抬起。上(shang)輥是由(you)高壓水缸來平衡(heng)的(de)(de)(de)，其(qi)(qi)升(sheng)降由(you)電動(dong)(dong)機(ji)(ji)操作，由(you)于芯(xin)棒(bang)全長有(you)1.6mm左右的(de)(de)(de)“退拔”，為使壁厚保持(chi)不變(bian)，軋(ya)制(zhi)時通過(guo)一個微(wei)調裝置(zhi)而將軋(ya)輥升(sheng)高，微(wei)調裝置(zhi)由(you)專(zhuan)用電動(dong)(dong)機(ji)(ji)和減速(su)箱(xiang)組成，減速(su)箱(xiang)的(de)(de)(de)出軸通過(guo)空(kong)氣離(li)合器與壓下(xia)螺絲(si)電動(dong)(dong)機(ji)(ji)的(de)(de)(de)軸相(xiang)連，軋(ya)制(zhi)時操作工將上(shang)軋(ya)輥逐漸(jian)抬高以補償芯(xin)棒(bang)的(de)(de)(de)錐度和熱膨(peng)脹(zhang)。
軋制過程中金屬流動(dong)的(de)(de)方(fang)向(xiang)與喂(wei)料的(de)(de)方(fang)向(xiang)相(xiang)同(tong)，軋輥(gun)每轉一周后，芯(xin)棒(bang)回(hui)轉90°左右。當空心坯被軋制并由芯(xin)棒(bang)前(qian)端向(xiang)前(qian)移動(dong)時，毛管(guan)(guan)繼(ji)續在導(dao)槽(cao)上滑移，空心坯完全軋成(cheng)管(guan)(guan)子后，上軋輥(gun)抬起，升降輥(gun)升起，將毛管(guan)(guan)輸送到熱鋸(ju)，切去端頭和皮(pi)爾格(ge)頭，然后測量和稱量管(guan)(guan)子，在管(guan)(guan)壁上標出測得(de)的(de)(de)重量。
