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(ya)管機組采用Phoenix 鋼鐵公(gong)司平爐頂(ding)鑄生產的(de)最大重量達8000磅的(de)波浪(lang)形鋼錠(ding)為(wei)原(yuan)料，成品管直徑為(wei)51/2~16英寸壁厚(hou)為(wei)1/4~3英寸。
這種軋管(guan)(guan)機組的一大特點是直接采用(yong)平爐鋼錠在一個連續的工藝過程(cheng)(cheng)(cheng)(cheng)中(zhong)軋制成(cheng)管(guan)(guan)，并且僅(jin)一次加(jia)熱(re)(re)就能完成(cheng)沖(chong)孔(kong)、延(yan)伸(shen)，周(zhou)期(qi)軋管(guan)(guan)各工藝過程(cheng)(cheng)(cheng)(cheng)，其主要(yao)工藝過程(cheng)(cheng)(cheng)(cheng)是：鋼錠清(qing)理、加(jia)熱(re)(re)、沖(chong)孔(kong)、延(yan)伸(shen)、周(zhou)期(qi)軋管(guan)(guan)，再加(jia)熱(re)(re)、定徑、修磨，精整和水壓(ya)試驗，以下主要(yao)論述沖(chong)孔(kong)、延(yan)伸(shen)和周(zhou)期(qi)軋管(guan)(guan)等三個工藝過程(cheng)(cheng)(cheng)(cheng)。
1. 水壓沖孔
鋼(gang)錠(ding)(ding)經(jing)火焰燒剝去除表面缺(que)陷后(hou)，在(zai)車(che)底式(shi)加熱(re)爐(lu)內(nei)(nei)加熱(re)到2340~2370℉。用(yong)小車(che)運送到沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)機(ji)(ji)上(shang)進(jin)行沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)操作。鋼(gang)錠(ding)(ding)在(zai)1200t水壓沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)機(ji)(ji)上(shang)沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)，其(qi)(qi)操作過程如(ru)下：用(yong)水壓操縱的(de)裝料機(ji)(ji)將(jiang)(jiang)鋼(gang)錠(ding)(ding)送人沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)機(ji)(ji)，將(jiang)(jiang)其(qi)(qi)置(zhi)于支架(jia)上(shang)的(de)沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)位(wei)置(zhi)，兩個(ge)支架(jia)中(zhong)有一(yi)個(ge)是(shi)固定在(zai)沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)模(mo)上(shang)的(de)，而另(ling)一(yi)個(ge)則(ze)可以(yi)伸縮，沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)模(mo)前(qian)移(yi)時即將(jiang)(jiang)鋼(gang)錠(ding)(ding)套住(zhu)，開始沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)操作。鋼(gang)錠(ding)(ding)沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)后(hou)，其(qi)(qi)形狀(zhuang)像杯(bei)子，被稱(cheng)為杯(bei)狀(zhuang)體，沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)模(mo)的(de)內(nei)(nei)徑(jing)決定杯(bei)狀(zhuang)體的(de)外徑(jing)。沖(chong)(chong)(chong)(chong)(chong)(chong)頭直(zhi)徑(jing)則(ze)確定杯(bei)狀(zhuang)體內(nei)(nei)孔(kong)(kong)的(de)直(zhi)徑(jing)，圖13-1所示是(shi)沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)模(mo)前(qian)移(yi)但尚未套上(shang)鋼(gang)錠(ding)(ding)前(qian)端時的(de)狀(zhuang)況，沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)模(mo)前(qian)移(yi)達到其(qi)(qi)沖(chong)(chong)(chong)(chong)(chong)(chong)程的(de)75%,可伸縮支架(jia)從下部(bu)移(yi)出，圖13-2示出鋼(gang)錠(ding)(ding)已(yi)被套入沖(chong)(chong)(chong)(chong)(chong)(chong)孔(kong)(kong)模(mo)內(nei)(nei)。
圖13-3示出整個杯狀(zhuang)體還套在沖孔模內的(de)(de)情況，從圖13-3可以看(kan)出被沖孔的(de)(de)鋼錠前端(duan)只剩下很薄的(de)(de)杯底。鋼錠呈方(fang)形(xing)或(huo)圓形(xing)，即直徑為13英(ying)寸(cun)，16英(ying)寸(cun)，19英(ying)寸(cun)和21英(ying)寸(cun)的(de)(de)波浪(lang)形(xing)圓錠。
2. 杯狀體延伸
在延伸機(ji)(ji)上，杯狀(zhuang)體在兩(liang)個在水平面(mian)上成反向傾(qing)斜的(de)斜置軋輥間，通過具有(you)(you)一定形狀(zhuang)的(de)頂頭進行軋制(zhi)。在垂直平面(mian)上有(you)(you)兩(liang)個固定導板(ban)，其作用是限(xian)制(zhi)變形區的(de)杯狀(zhuang)體的(de)斷(duan)面(mian)形狀(zhuang)使(shi)之不至于過分橢圓。這種延伸機(ji)(ji)與曼(man)內斯曼(man)斜軋穿(chuan)孔機(ji)(ji)很相似，它(ta)可以(yi)延伸杯狀(zhuang)體，并穿(chuan)透杯底使(shi)之成為空(kong)心坯(pi)。
圖13-4示出(chu)采用(yong)(yong)曼(man)內(nei)斯曼(man)輥型的(de)延伸(shen)機對杯(bei)狀體進行延伸(shen)的(de)過(guo)程。圖13-5所示是采用(yong)(yong)了Calmes軋輥的(de)情況，空(kong)心(xin)坯延伸(shen)時，最好選用(yong)(yong)延伸(shen)率 λ＝1.75,最大不超過(guo)2。
延伸機(ji)采用3相(xiang)、60Hz、功率(lv)為2208kW(3000馬力(li)）的同步(bu)電機(ji)傳動，額定電壓、轉(zhuan)速分(fen)別為6900V,1500r/min,減速機(ji)的速比(bi)為3。
延伸機(ji)的主要特點之一是它(ta)所(suo)生產的空(kong)心坯(pi)壁厚(hou)比較均勻(yun)。斜(xie)軋延伸機(ji)的延伸過程可(ke)參看圖13-6。
杯(bei)狀體離(li)開(kai)軋(ya)輥(gun)成為空心(xin)(xin)坯(pi)后，用以(yi)夾持頂桿的鎖門就打開(kai)，空心(xin)(xin)坯(pi)從延(yan)伸機輸出(chu)，用橫移小車將其(qi)運送(song)到周期軋(ya)管機。
3. 周(zhou)期軋管(guan)(guan)機軋管(guan)(guan)
周期軋(ya)管(guan)(guan)機(ji)由一臺額定功(gong)率為1472kW(2000馬力）的(de)(de)(de)電(dian)動機(ji)傳動，該(gai)電(dian)動機(ji)的(de)(de)(de)功(gong)率能(neng)達2208kW(3000馬力）而不至于過分發熱。電(dian)動機(ji)軸(zhou)上配有飛輪，在每一轉中它既提供(gong)能(neng)量又獲得能(neng)量，軋(ya)機(ji)速(su)度(du)(du)是(shi)30~105r/min,較低的(de)(de)(de)速(su)度(du)(du)用于軋(ya)制(zhi)大管(guan)(guan)，而較高(gao)的(de)(de)(de)速(su)度(du)(du)用來軋(ya)小管(guan)(guan)。操作(zuo)喂(wei)(wei)料(liao)器(qi)(qi)的(de)(de)(de)高(gao)壓(ya)(ya)水(shui)壓(ya)(ya)力為2800 Ibl/in或1500 Ibf/in,以(yi)向(xiang)(xiang)一個前進(jin)(jin)缸(gang)和兩(liang)個回(hui)(hui)程缸(gang)供(gong)水(shui)，正常運轉時，向(xiang)(xiang)前進(jin)(jin)缸(gang)連續地供(gong)高(gao)壓(ya)(ya)水(shui)，向(xiang)(xiang)前喂(wei)(wei)料(liao)時，高(gao)壓(ya)(ya)水(shui)由回(hui)(hui)程缸(gang)流(liu)出，因此向(xiang)(xiang)前喂(wei)(wei)料(liao)的(de)(de)(de)速(su)度(du)(du)受到從(cong)(cong)回(hui)(hui)程缸(gang)排出的(de)(de)(de)高(gao)壓(ya)(ya)水(shui)量的(de)(de)(de)控制(zhi)。這一操作(zuo)在咬(yao)人時是(shi)手工(gong)操作(zuo)，由操作(zuo)工(gong)自(zi)行控制(zhi)，軋(ya)制(zhi)時則(ze)是(shi)自(zi)動操作(zuo)的(de)(de)(de)，操作(zuo)工(gong)應使(shi)喂(wei)(wei)料(liao)器(qi)(qi)的(de)(de)(de)前進(jin)(jin)速(su)度(du)(du)與軋(ya)輥的(de)(de)(de)速(su)度(du)(du)同步；此外，操作(zuo)工(gong)還必須控制(zhi)空(kong)氣壓(ya)(ya)力p1,空(kong)心坯咬(yao)人時，迅速(su)把空(kong)氣從(cong)(cong)缸(gang)里排出，開始軋(ya)制(zhi)后(hou)，根據所軋(ya)管(guan)(guan)子的(de)(de)(de)規格調整空(kong)氣壓(ya)(ya)力P1.液壓(ya)(ya)自(zi)動喂(wei)(wei)料(liao)器(qi)(qi)斷面示意圖如圖13-7所示。
該喂(wei)料器的一個特點是(shi)，空氣缸的沖(chong)程長(chang)(chang)(chang)度(du)(du)(du)都保持(chi)不變。軋(ya)(ya)(ya)(ya)制(zhi)152~203mm管子(zi)時(shi)沖(chong)程長(chang)(chang)(chang)度(du)(du)(du)為(wei)762mm,而軋(ya)(ya)(ya)(ya)制(zhi)228~406mm的管子(zi)時(shi)，則沖(chong)程長(chang)(chang)(chang)度(du)(du)(du)為(wei)838mm.這意味著軋(ya)(ya)(ya)(ya)輥工作段長(chang)(chang)(chang)度(du)(du)(du)是(shi)恒定不變的，在(zai)軋(ya)(ya)(ya)(ya)輥車床上凸輪的安裝(zhuang)位置恰(qia)可使(shi)軋(ya)(ya)(ya)(ya)輥的工作段和所(suo)對(dui)應的喂(wei)料器一致。喂(wei)料的方向(xiang)與軋(ya)(ya)(ya)(ya)輥旋(xuan)轉的方向(xiang)是(shi)相反(fan)的，軋(ya)(ya)(ya)(ya)機操作工控(kong)制(zhi)喂(wei)料速(su)度(du)(du)(du)并將此(ci)速(su)度(du)(du)(du)和軋(ya)(ya)(ya)(ya)輥轉速(su)保持(chi)同(tong)步(bu)。芯棒(bang)(bang)長(chang)(chang)(chang)度(du)(du)(du)為(wei)4572~4877mm,同(tong)時(shi)使(shi)用的芯棒(bang)(bang)為(wei)5根(gen)(gen)(gen)，其中(zhong)一根(gen)(gen)(gen)芯棒(bang)(bang)用于軋(ya)(ya)(ya)(ya)制(zhi)，其余芯棒(bang)(bang)在(zai)空氣中(zhong)冷卻(que)，然后浸(jin)人水中(zhong)進一步(bu)冷卻(que)，一般(ban)是(shi)3根(gen)(gen)(gen)芯棒(bang)(bang)在(zai)空氣中(zhong)冷卻(que)，一根(gen)(gen)(gen)芯棒(bang)(bang)在(zai)水里冷卻(que)，軋(ya)(ya)(ya)(ya)機運行中(zhong)5根(gen)(gen)(gen)芯棒(bang)(bang)就這樣反(fan)復循(xun)環著。
根據(ju)所軋(ya)(ya)管子規(gui)格調下輥(gun)(gun)高(gao)度，調整后(hou)(hou)其高(gao)度是不(bu)變的。當(dang)空心坯被軋(ya)(ya)成(cheng)帶(dai)有皮(pi)爾(er)格頭的管子后(hou)(hou)，應將上(shang)(shang)輥(gun)(gun)抬起。上(shang)(shang)輥(gun)(gun)是由(you)高(gao)壓水缸來平衡的，其升(sheng)降(jiang)由(you)電動(dong)機(ji)操(cao)作(zuo)，由(you)于芯(xin)棒全長(chang)有1.6mm左(zuo)右的“退拔”，為使壁厚保持(chi)不(bu)變，軋(ya)(ya)制時通過一個微調裝置而將軋(ya)(ya)輥(gun)(gun)升(sheng)高(gao)，微調裝置由(you)專用電動(dong)機(ji)和減速箱(xiang)組成(cheng)，減速箱(xiang)的出軸(zhou)通過空氣離合器(qi)與壓下螺(luo)絲(si)電動(dong)機(ji)的軸(zhou)相連(lian)，軋(ya)(ya)制時操(cao)作(zuo)工將上(shang)(shang)軋(ya)(ya)輥(gun)(gun)逐漸抬高(gao)以補(bu)償(chang)芯(xin)棒的錐度和熱膨脹。
軋制(zhi)過程中金屬(shu)流動的(de)方向與喂料的(de)方向相(xiang)同，軋輥每轉(zhuan)(zhuan)一周后，芯棒(bang)回(hui)轉(zhuan)(zhuan)90°左右。當空心坯(pi)被(bei)軋制(zhi)并由芯棒(bang)前端向前移動時，毛管(guan)繼續(xu)在導槽上(shang)(shang)滑移，空心坯(pi)完全軋成管(guan)子后，上(shang)(shang)軋輥抬起，升降輥升起，將毛管(guan)輸送到熱(re)鋸，切去端頭(tou)和皮爾格(ge)頭(tou)，然后測量(liang)和稱(cheng)量(liang)管(guan)子，在管(guan)壁上(shang)(shang)標出測得(de)的(de)重量(liang)。
