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(guan)(guan)機(ji)組采用(yong)Phoenix 鋼鐵公司平爐頂鑄(zhu)生產的最大重量達8000磅(bang)的波浪形鋼錠為原(yuan)料，成品管(guan)(guan)直徑為51/2~16英寸(cun)(cun)壁厚為1/4~3英寸(cun)(cun)。
這種軋(ya)管(guan)(guan)(guan)機組的(de)一大(da)特點(dian)是(shi)直接(jie)采用平爐鋼錠在一個連(lian)續(xu)的(de)工(gong)(gong)(gong)藝過程中軋(ya)制成(cheng)管(guan)(guan)(guan)，并(bing)且僅一次加熱就能(neng)完(wan)成(cheng)沖(chong)孔、延伸，周(zhou)(zhou)期(qi)軋(ya)管(guan)(guan)(guan)各工(gong)(gong)(gong)藝過程，其主要工(gong)(gong)(gong)藝過程是(shi)：鋼錠清理、加熱、沖(chong)孔、延伸、周(zhou)(zhou)期(qi)軋(ya)管(guan)(guan)(guan)，再加熱、定徑、修磨，精整和水(shui)壓試驗(yan)，以下(xia)主要論述沖(chong)孔、延伸和周(zhou)(zhou)期(qi)軋(ya)管(guan)(guan)(guan)等三個工(gong)(gong)(gong)藝過程。
1. 水壓沖孔(kong)
鋼錠(ding)(ding)(ding)經(jing)火焰燒剝去除表面缺陷后(hou)，在(zai)車底(di)式(shi)加熱爐內加熱到(dao)(dao)2340~2370℉。用小車運送到(dao)(dao)沖(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)機上進行沖(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)操作。鋼錠(ding)(ding)(ding)在(zai)1200t水(shui)壓(ya)沖(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)機上沖(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)，其操作過程(cheng)如下：用水(shui)壓(ya)操縱(zong)的(de)(de)(de)裝(zhuang)料機將鋼錠(ding)(ding)(ding)送人沖(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)機，將其置于支(zhi)架上的(de)(de)(de)沖(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)位(wei)置，兩個支(zhi)架中有一個是固定在(zai)沖(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)模(mo)(mo)上的(de)(de)(de)，而另一個則可以伸縮，沖(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)模(mo)(mo)前移時即(ji)將鋼錠(ding)(ding)(ding)套(tao)住，開始沖(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)操作。鋼錠(ding)(ding)(ding)沖(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)后(hou)，其形(xing)狀(zhuang)(zhuang)像杯子，被稱(cheng)為杯狀(zhuang)(zhuang)體，沖(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)模(mo)(mo)的(de)(de)(de)內徑(jing)(jing)決(jue)定杯狀(zhuang)(zhuang)體的(de)(de)(de)外(wai)徑(jing)(jing)。沖(chong)(chong)(chong)頭直徑(jing)(jing)則確定杯狀(zhuang)(zhuang)體內孔(kong)(kong)(kong)(kong)的(de)(de)(de)直徑(jing)(jing)，圖13-1所示是沖(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)模(mo)(mo)前移但尚未(wei)套(tao)上鋼錠(ding)(ding)(ding)前端時的(de)(de)(de)狀(zhuang)(zhuang)況，沖(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)模(mo)(mo)前移達到(dao)(dao)其沖(chong)(chong)(chong)程(cheng)的(de)(de)(de)75%,可伸縮支(zhi)架從下部移出，圖13-2示出鋼錠(ding)(ding)(ding)已被套(tao)入(ru)沖(chong)(chong)(chong)孔(kong)(kong)(kong)(kong)模(mo)(mo)內。
圖13-3示出(chu)整個杯(bei)狀體還(huan)套在沖(chong)孔模內的情況(kuang)，從(cong)圖13-3可(ke)以看(kan)出(chu)被沖(chong)孔的鋼錠前端只(zhi)剩(sheng)下很薄的杯(bei)底。鋼錠呈方形或圓形，即直徑為13英寸，16英寸，19英寸和21英寸的波浪形圓錠。
2. 杯狀體延伸(shen)
在(zai)(zai)延(yan)伸(shen)機(ji)上(shang)，杯狀體在(zai)(zai)兩個在(zai)(zai)水平(ping)面(mian)上(shang)成反向傾斜(xie)的(de)斜(xie)置軋(ya)輥間，通過具(ju)有(you)一定(ding)形(xing)狀的(de)頂頭進(jin)行軋(ya)制(zhi)。在(zai)(zai)垂直平(ping)面(mian)上(shang)有(you)兩個固定(ding)導板，其作用(yong)是限制(zhi)變形(xing)區的(de)杯狀體的(de)斷面(mian)形(xing)狀使(shi)之不至于過分橢圓。這種延(yan)伸(shen)機(ji)與曼內斯曼斜(xie)軋(ya)穿(chuan)(chuan)孔機(ji)很相似，它可以延(yan)伸(shen)杯狀體，并穿(chuan)(chuan)透杯底使(shi)之成為空心(xin)坯。
圖(tu)13-4示出采用曼內(nei)斯曼輥型的延(yan)伸(shen)機對杯狀(zhuang)體進行延(yan)伸(shen)的過程。圖(tu)13-5所示是采用了Calmes軋輥的情況，空(kong)心坯延(yan)伸(shen)時，最好選用延(yan)伸(shen)率 λ＝1.75,最大(da)不超過2。
延伸機(ji)采用3相、60Hz、功率為2208kW(3000馬(ma)力）的(de)同步電機(ji)傳動(dong)，額定電壓、轉(zhuan)速分別為6900V,1500r/min,減速機(ji)的(de)速比為3。
延(yan)(yan)伸機的主要特點之一是它所生產(chan)的空心(xin)坯壁厚(hou)比較均(jun)勻。斜(xie)軋延(yan)(yan)伸機的延(yan)(yan)伸過程可參(can)看圖13-6。
杯狀體離開軋輥(gun)成(cheng)為空心(xin)坯后，用以夾(jia)持頂(ding)桿的(de)鎖門就(jiu)打開，空心(xin)坯從(cong)延(yan)伸機輸(shu)出，用橫移小車將其運送到周期軋管機。
3. 周期軋管(guan)機軋管(guan)
周期軋(ya)(ya)管(guan)機(ji)由一臺額定功(gong)率(lv)為(wei)1472kW(2000馬(ma)力）的(de)(de)(de)電(dian)動機(ji)傳動，該電(dian)動機(ji)的(de)(de)(de)功(gong)率(lv)能達2208kW(3000馬(ma)力）而(er)不(bu)至于(yu)過(guo)分發熱。電(dian)動機(ji)軸(zhou)上配有(you)飛輪，在每一轉中它(ta)既提供(gong)能量又獲(huo)得能量，軋(ya)(ya)機(ji)速(su)(su)度是30~105r/min,較(jiao)低(di)的(de)(de)(de)速(su)(su)度用于(yu)軋(ya)(ya)制(zhi)(zhi)大管(guan)，而(er)較(jiao)高(gao)(gao)的(de)(de)(de)速(su)(su)度用來軋(ya)(ya)小管(guan)。操(cao)作(zuo)(zuo)喂(wei)料(liao)器(qi)的(de)(de)(de)高(gao)(gao)壓(ya)(ya)水(shui)壓(ya)(ya)力為(wei)2800 Ibl/in或1500 Ibf/in,以向(xiang)(xiang)一個前(qian)進(jin)(jin)缸(gang)和(he)兩(liang)個回(hui)程(cheng)(cheng)缸(gang)供(gong)水(shui)，正常運轉時(shi)(shi)(shi)，向(xiang)(xiang)前(qian)進(jin)(jin)缸(gang)連續地供(gong)高(gao)(gao)壓(ya)(ya)水(shui)，向(xiang)(xiang)前(qian)喂(wei)料(liao)時(shi)(shi)(shi)，高(gao)(gao)壓(ya)(ya)水(shui)由回(hui)程(cheng)(cheng)缸(gang)流(liu)出，因此向(xiang)(xiang)前(qian)喂(wei)料(liao)的(de)(de)(de)速(su)(su)度受到(dao)從(cong)回(hui)程(cheng)(cheng)缸(gang)排(pai)出的(de)(de)(de)高(gao)(gao)壓(ya)(ya)水(shui)量的(de)(de)(de)控(kong)制(zhi)(zhi)。這一操(cao)作(zuo)(zuo)在咬人(ren)時(shi)(shi)(shi)是手工(gong)操(cao)作(zuo)(zuo)，由操(cao)作(zuo)(zuo)工(gong)自行控(kong)制(zhi)(zhi)，軋(ya)(ya)制(zhi)(zhi)時(shi)(shi)(shi)則是自動操(cao)作(zuo)(zuo)的(de)(de)(de)，操(cao)作(zuo)(zuo)工(gong)應使喂(wei)料(liao)器(qi)的(de)(de)(de)前(qian)進(jin)(jin)速(su)(su)度與軋(ya)(ya)輥的(de)(de)(de)速(su)(su)度同步；此外，操(cao)作(zuo)(zuo)工(gong)還必須控(kong)制(zhi)(zhi)空(kong)(kong)氣壓(ya)(ya)力p1,空(kong)(kong)心(xin)坯咬人(ren)時(shi)(shi)(shi)，迅速(su)(su)把空(kong)(kong)氣從(cong)缸(gang)里排(pai)出，開始(shi)軋(ya)(ya)制(zhi)(zhi)后，根(gen)據所軋(ya)(ya)管(guan)子的(de)(de)(de)規格調整空(kong)(kong)氣壓(ya)(ya)力P1.液壓(ya)(ya)自動喂(wei)料(liao)器(qi)斷(duan)面示(shi)意圖如圖13-7所示(shi)。
該喂料器的(de)(de)(de)一(yi)(yi)個特點(dian)是(shi)，空(kong)氣缸的(de)(de)(de)沖程長(chang)度(du)(du)(du)都(dou)保持(chi)不變。軋(ya)(ya)制152~203mm管子(zi)時(shi)沖程長(chang)度(du)(du)(du)為(wei)(wei)762mm,而軋(ya)(ya)制228~406mm的(de)(de)(de)管子(zi)時(shi)，則沖程長(chang)度(du)(du)(du)為(wei)(wei)838mm.這意味著(zhu)軋(ya)(ya)輥(gun)工作段(duan)長(chang)度(du)(du)(du)是(shi)恒定不變的(de)(de)(de)，在(zai)軋(ya)(ya)輥(gun)車床上(shang)凸輪的(de)(de)(de)安裝位置恰可使(shi)(shi)軋(ya)(ya)輥(gun)的(de)(de)(de)工作段(duan)和所對應的(de)(de)(de)喂料器一(yi)(yi)致。喂料的(de)(de)(de)方向與軋(ya)(ya)輥(gun)旋轉的(de)(de)(de)方向是(shi)相(xiang)反的(de)(de)(de)，軋(ya)(ya)機操作工控制喂料速度(du)(du)(du)并將此(ci)速度(du)(du)(du)和軋(ya)(ya)輥(gun)轉速保持(chi)同步(bu)。芯(xin)棒(bang)(bang)(bang)長(chang)度(du)(du)(du)為(wei)(wei)4572~4877mm,同時(shi)使(shi)(shi)用(yong)的(de)(de)(de)芯(xin)棒(bang)(bang)(bang)為(wei)(wei)5根(gen)，其中一(yi)(yi)根(gen)芯(xin)棒(bang)(bang)(bang)用(yong)于(yu)軋(ya)(ya)制，其余芯(xin)棒(bang)(bang)(bang)在(zai)空(kong)氣中冷(leng)(leng)卻(que)，然后浸人水(shui)中進一(yi)(yi)步(bu)冷(leng)(leng)卻(que)，一(yi)(yi)般是(shi)3根(gen)芯(xin)棒(bang)(bang)(bang)在(zai)空(kong)氣中冷(leng)(leng)卻(que)，一(yi)(yi)根(gen)芯(xin)棒(bang)(bang)(bang)在(zai)水(shui)里冷(leng)(leng)卻(que)，軋(ya)(ya)機運行中5根(gen)芯(xin)棒(bang)(bang)(bang)就(jiu)這樣反復循環著(zhu)。
根(gen)據所軋(ya)(ya)(ya)管(guan)子(zi)規(gui)格(ge)調(diao)(diao)下輥(gun)(gun)高(gao)度，調(diao)(diao)整后其(qi)高(gao)度是不變的。當空心坯被軋(ya)(ya)(ya)成帶(dai)有(you)皮(pi)爾(er)格(ge)頭(tou)的管(guan)子(zi)后，應(ying)將(jiang)上輥(gun)(gun)抬起。上輥(gun)(gun)是由(you)高(gao)壓水(shui)缸來平衡的，其(qi)升降由(you)電動(dong)機操(cao)作(zuo)，由(you)于(yu)芯棒全長有(you)1.6mm左右的“退拔”，為(wei)使壁厚保持不變，軋(ya)(ya)(ya)制時通過一(yi)個微調(diao)(diao)裝置(zhi)而將(jiang)軋(ya)(ya)(ya)輥(gun)(gun)升高(gao)，微調(diao)(diao)裝置(zhi)由(you)專用電動(dong)機和減速箱(xiang)組(zu)成，減速箱(xiang)的出軸(zhou)通過空氣離合(he)器與(yu)壓下螺絲電動(dong)機的軸(zhou)相連，軋(ya)(ya)(ya)制時操(cao)作(zuo)工將(jiang)上軋(ya)(ya)(ya)輥(gun)(gun)逐(zhu)漸抬高(gao)以補償芯棒的錐度和熱膨脹。
軋制(zhi)(zhi)過程中(zhong)金屬流動(dong)的(de)方向與(yu)喂料(liao)的(de)方向相同，軋輥(gun)每(mei)轉(zhuan)(zhuan)一周后，芯棒回(hui)轉(zhuan)(zhuan)90°左右。當空心坯(pi)被(bei)軋制(zhi)(zhi)并(bing)由芯棒前端向前移(yi)動(dong)時，毛管(guan)繼(ji)續(xu)在導(dao)槽(cao)上滑(hua)移(yi)，空心坯(pi)完全軋成管(guan)子后，上軋輥(gun)抬起(qi)，升降(jiang)輥(gun)升起(qi)，將(jiang)毛管(guan)輸送到熱鋸(ju)，切(qie)去端頭和(he)皮(pi)爾格頭，然后測量(liang)和(he)稱量(liang)管(guan)子，在管(guan)壁上標(biao)出測得(de)的(de)重量(liang)。
