Project application report

Production line construction project project report I. Project overview

1. Project Name: Aluminum and aluminum alloy forging production line

2, the main products: all forgings and die forgings of all aluminum alloy

3. Production scale: 15000T/year

4. Construction investment amount: 150 million yuan

Second, the reasons and main content of the project

1. Purpose of the project

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 that require high force and high mechanical properties are manufactured by forging.

The weight of the upper forging part of the aircraft accounts for 80%, the weight of the upper part of the tank accounts for 70%, and the weight of the forged part of the automobile accounts for 60%. The turbine main shaft, turbine impeller, rotor and retaining ring in the power industry are forged. As can be seen from these examples, forging production plays a very important role in the industrial sector.

Aluminum alloys have been widely used in various industrial sectors due to their small specific gravity, specific strength and high specific stiffness. Aluminum forgings have become an indispensable material for mechanical parts in various industrial sectors. All kinds of forgings that can be forged with low carbon steel can be forged from aluminum alloy. The aluminum alloy can be forged on various forging equipment such as forging hammer, mechanical press, hydraulic press, top forging machine, reaming machine, etc., and can be free forging, die forging, upsetting, roll forging and reaming. In general, aluminum forgings with small size, simple shape, and poor deviation requirements can be easily forged on the forging hammer. However, for aluminum forgings with large specifications and requiring severe deformation, a hydraulic press should be used for forging. For large forging and integral aluminum forgings, it is not possible to use large die forging hydraulic presses. Especially in the past ten years, with the advancement of science and technology and the development of the national economy, higher and higher requirements have been placed on materials, forcing aluminum alloy forgings to develop in the direction of large-scale integration, high-strength, high-toughening, and complex precision. Greatly promoted the development of large and medium-sized hydraulic presses.

With the development of China's transportation industry in the direction of modernization and high-speed, the requirements for lightweighting of transportation tools are becoming stronger and stronger, and the voice of aluminum-based steel is getting louder and louder. In particular, important parts and structural components of aircraft, spacecraft, railway vehicles, underground railways, high-speed trains, freight cars, automobiles, ships, ships, artillery, tanks, and mechanical equipment, which are highly lightweight, have been in recent years. Aluminum and aluminum alloy forgings are used to replace the original steel structural members. For example, aircraft structural parts are almost all aluminum alloy die forgings; automobile wheels, bumpers, base girders; tank floating wheels, turret stands; helicopter moving rings and The moving ring; the cylinder and piston skirt of the train; the woodworking machinery body; the machine base, the track and the stranding plate of the textile machine are all made by applying aluminum alloy die forgings. Moreover, this trend is growing substantially, and even some aluminum alloy castings have begun to be replaced by aluminum alloy die forgings.

At present, there are only a few large-scale forging hydraulic presses in the world, and there are few in China. With the modernization of the national defense industry and the development of the civilian industry, especially the transportation industry, the varieties and output of aluminum alloy die forgings can not only meet the domestic market. Need, the international market also has a big gap. Therefore, it is very necessary and timely to build several large and medium-sized aluminum alloy forging production lines in China, which has great practical significance and long-term significance for the rapid development of the national economy and the modernization of national defense military industry.

2. The 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, the alloys, state, varieties, specifications, properties and uses of aluminum alloy forgings and die forgings and production processes and Key technologies for analysis and selection, configuration of reasonable and economical host and auxiliary equipment and water, wind, electricity, gas and other ancillary facilities, construction of workshops and installation and commissioning of equipment, and finally production of quality that is urgently needed by the country and required by domestic and foreign markets. Large and medium-sized aluminum alloy forgings and die forgings. Proper consideration of the production of titanium alloys, superalloys and steel forgings.

The goal of the project is to build a modern production line of large and medium-sized aluminum alloy forgings and die forgings with an annual output of 15,000 T/a, and provide large quantities of qualified new materials for the national defense industry and the national economy departments to meet the needs of domestic and foreign markets.

Third, the characteristics of aluminum alloy forgings, the scope of application and market analysis

1. Characteristics of aluminum alloy forgings

1) The density is small, 34% of steel forgings and 30% of copper forgings are ideal materials for lightweighting;

2) The specific strength is large, the specific stiffness is larger, the specific modulus is larger than the elastic modulus, and the fatigue strength is high. It is suitable for the key parts with high requirements for lightweighting, and its comprehensive performance is much higher than other materials.

3) The internal organization is fine, uniform and defect-free, and its reliability is much higher than that of aluminum alloy castings and die-casting parts, and higher than other material forgings.

4) The aluminum alloy has good plasticity and can be processed into high-precision forgings with various shapes and complexities. The machining allowance is small, only about 20% of the processing capacity of the aluminum alloy tensile thick plate, 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 and beautiful, the surface treatment performance is good, beautiful and durable.

It can be seen that aluminum forgings have a series of excellent features, which provide good conditions for aluminum forgings instead of steel, copper, magnesium, wood and plastic.

2, the field of aluminum alloy forgings

In recent years, due to the decline in the cost of aluminum, the performance has improved, and the variety specifications have expanded, and the field of application has become larger and larger. Mainly used in aerospace, transportation, automotive, marine, energy power, electronic communications, petrochemical, metallurgical mining, machinery and electrical appliances. The characteristics and uses of the main forged aluminum alloy are shown in Table 1.

Table 1 Characteristics and uses of forged aluminum alloy

Classification and gold and state strength corrosion resistance chip solderability characteristics main use

High strength

alloy
2024-T6
B
C
A
D
Forging, plasticity, poor corrosion resistance, is a typical hard aluminum alloy aircraft parts, railway vehicles, automotive parts, general structural parts

7075-T6
A
C
A
D
Super hard forged alloy, corrosion resistance, stress corrosion cracking, poor aircraft parts, aerospace materials, structural components

7075-T73
B
B
A
D
Improved stress corrosion cracking resistance by proper aging treatment, strength lower than T6
Aircraft, ships, auto parts, structural parts

7175-T736
A
B
A
D
New alloy aircraft parts, aerospace materials and load-bearing parts with excellent strength, toughness and stress corrosion crack resistance

Heat resistant

alloy
2219-T6
B
B
A
A
Excellent strength and creep resistance at high temperatures, good weldability, aircraft, rocket parts and vehicle materials

2618-T6
B
C
A
C
Excellent high temperature strength piston, supercharger fan, rubber mold, general heat resistant parts

4032-T6
C
C
C
B
High strength at medium temperature, low coefficient of thermal expansion, good wear resistance, piston and wear parts

Corrosion resistant

alloy
1100-0
D
A
C
A
Low strength, corrosion resistance, good heat and cold workability, poor chipping electronic communication parts, memory drums for electronic computers, etc.

5083-0
C
A
C
A
Corrosion resistance, weldability and low temperature mechanical properties, typical naval alloy LNG flanges and petrochemical machinery, ship parts and desalination structures

6061-T6
C
A
B
A
Medium strength, corrosion resistance, fatigue resistance, good overall performance, aerospace, automotive materials and rotor parts

6051-T6
C
A
B
A
Excellent toughness and corrosion resistance, slightly higher than 6061
Supercharger fan, transport machinery parts, etc.

Note: A-excellent; B-good; C-general; D-poor

3. Market analysis

1) Analysis of production and sales of aluminum alloy forgings

Due to the above series of advantages, aluminum and alloy forgings are favored in the aerospace, automotive, marine, transportation, weapons, telecommunications and other industrial sectors, and the scope of application is more and more extensive. According to preliminary statistics, aluminum forgings rose from 0.5% in 1985 to around 15% in 2002. At present, the world consumes about 3.44 million tons of forgings, of which aluminum forgings account for about 500,000 t/a. Titanium forgings and high-temperature forgings account for about 0.5%, or about 18,000 t/a, and steel forgings still account for the vast majority. From the point of view of the aluminum processing industry, the current global aluminum production is more than 30 million t / a, of which 80% will become processed materials, that is, the annual production of processed aluminum in the world is about 24 million t / a, of which the board, Belts and foils account for about 57%, and extruded materials account for about 38%. Due to the high cost and high production technology, aluminum alloy forging materials are only used in particularly important stress-bearing parts. For more than a decade, due to the needs of military and civilian industries, especially the modernization and lightweight of the transportation industry, The demand for aluminum-based steel is very urgent, and as a result, aluminum forgings and casings have experienced rapid growth. 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 growing demands of military and civilian departments for aluminum and aluminum alloy forgings, countries around the world are focusing on manpower, material resources and financial resources to develop aluminum forging production, design and manufacture of various forging equipment, especially large and medium-sized hydraulic forging presses. However, because the forging equipment is relatively expensive, the manufacturing cycle is long, and the forging production technology is relatively complicated, it is difficult to meet the market demand. At present, the production capacity of aluminum forgings in the world is about 300,000 t/a, which cannot meet the demand of 500,000 t/a. Due to the small and medium-sized hydraulic forging equipment and low production capacity, China is far from meeting the demand of aluminum forgings in the industrial sector. The annual gap is more than 15,000 t/a. By 2019, due to the large increase in automobiles, airplanes and ships in China, the annual consumption of aluminum forgings may reach 50,000 t/a or more.

2) Market analysis

From the above analysis, aluminum and aluminum alloy forgings are mainly used in industrial sectors requiring a large degree of weight reduction. According to the current application situation of countries, the main market distributions are as follows.

1 Aviation forgings: Forgings on aircraft account for more than 80% of the weight of aircraft materials, such as landing gear, frames, ribs, engine moving rings, moving rings, etc., thousands of forgings used on an aircraft, except for a few high-temperature components Most of the superalloys and titanium alloy forgings have been aluminized. For example, the company is a British company, with an annual output of thousands of aircraft, and the annual consumption of aluminum alloy forgings is tens of thousands of tons. Military aircraft and civilian aircraft such as fighter planes developed in China are also developing rapidly, and the aluminum forgings that need to be consumed will also increase year by year.

2 Aerospace forgings: Forgings on spacecraft are mainly forged rings, rims, spars and stands, most of which are aluminum forgings, only a few titanium forgings. The development of spacecraft, rockets, missiles, satellites, etc. has increased the demand for aluminum forgings. For example, in recent years, China's ultra-long-range missiles use AI-Li alloy casing forgings, each weighing more than 300 kilograms, worth several hundred thousand yuan.

3 weapon industry: such as tanks, armored vehicles, personnel carriers, chariots, rockets, gun frames, warships and other conventional weapons, the use of aluminum alloy forgings as a bearing capacity has greatly increased, basically replacing steel forgings.

4 Cars are the most promising industry for the use of aluminum alloy forgings and the largest users of aluminum forgings. Mainly used as wheels, bumpers, base beams and other small and medium-sized aluminum forgings, among which aluminum wheels are the largest aluminum forgings, mainly used in buses, trucks and heavy vehicles. In recent years, it has also been applied in small and medium-sized cars, locomotives 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 large auto companies such as FAW and Second Automobile are starting research and development. As the production of automobiles increases, the amount of aluminum wheels and other aluminum forgings will be dramatically improved.

5 In the energy power industry, aluminum forgings will gradually replace some steel forgings, such as frame, retaining ring, moving ring and non-moving ring, as well as coal transportation wheels, liquefied natural gas flanges, and generally large and medium forgings.

6 A large number of aluminum forgings are used on ships and ships for racks, moving rings, non-moving rings, and turrets.

7 In the machinery manufacturing industry, it is mainly used for woodworking machinery, textile machinery, etc. for racks, sliders, connecting rods, and cross-line climbing, etc., only for the aluminum forgings of textile machines, China needs tens of thousands of pieces every year. It weighs 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, with an annual consumption of 10,000 tons.

Fourth, the development of forging production

1. Foreign development status and level

Forging production is a very old industry, but the mass production of aluminum forgings began only in the 1950s. After decades of modernization, in terms of industrial equipment, mold design and manufacturing, production technology and technology, it has also developed rapidly in terms of product specifications, production scale and quality, especially in the United States, Russia, The development level of forging production in Germany, Japan, France, Italy, Czech Republic, Austria, Switzerland and other countries has reached a fairly high level. At present, there are hundreds of forging factories and thousands of forging machines in the world, with an annual output of nearly 5 million t/a forgings, of which 300,000 t/a for aluminum alloy die forgings. There are more than 500 large-scale hydraulic forging presses in the world, including more than 40 large-scale hydraulic forging presses of 100 MN or more, and about 20 medium-sized hydraulic forging presses of 300 MN or more. The distribution of heavy forging presses above 300 MN is: 4 in Russia, one of which is 750 MN, the highest in the world; 5 in the United States, including 2 450 MN; 1 in France, 650 MN; 2 in Germany; China 1 Taiwan; 1 in Romania; 1 in the UK. The main features of these forging hydraulic presses are compact structure, multi-function, high degree of automation, equipped with operating machine, rapid die changing device, reasonable plane configuration machine, favorable continuous operation and high production efficiency. In addition, with the increase in the size and precision of aluminum alloy die forgings, large-scale precision multi-directional die forging presses have received increasing attention. Countries have owned many large-scale multi-directional die hydraulic presses, including 3 in the US and 300 MN in maximum; It is 650 MN; one in the UK is 300 MN; one in China is 100 MN; two in Russia are 200 MN and 500 MN; and one in Germany is 350 MN. Multi-directional die forging press belongs to precision forging equipment, equipped with PLC system and computer control system, which can automatically adjust energy, stroke, pressure and speed, control the optimal working point of key components, monitor and display each working state. It predicts and protects system failure, equipment overload, over temperature and out of control, and controls the quality of products. 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 of the whole machine or the whole machine column, or even the entire workshop. Scientific management.

Developed a large number of new forging and new technologies in aluminum and aluminum alloy forging technology, such as liquid die forging, isothermal forging, powder forging, multi-directional die forging, non-slope precision die forging, partial die forging, and packaging. The combination of die forging, etc., has played a major role in simplifying the process, reducing the process, saving energy, expanding quality, increasing specifications, improving quality and production efficiency, protecting the environment, reducing labor intensity, and improving economic efficiency. The special computer software provides reliable guarantee for controlling the main process parameters such as forging temperature, forging pressure, deformation degree and process lubrication, controlling the size of the product and internal organization and mechanical properties.

The design and manufacture of forging dies is the key to aluminum forging technology. The CAD/CAM system for forgings is very mature and popular. In the United States, CAD/CAM systems are being replaced by CIM. CIM includes complete sets of technology, computer technology, CAD/CAM technology, robots, expert systems, processing plans, control systems and automatic material processing, which provide conditions for optimal design and process improvement of die forgings. For example, in the automotive industry, the design and process optimization of the front beam, the horn, the hub, the crankshaft, etc., can reduce the weight of the improved horns by 15%, the hub weight by 30%, and the crankshaft weight loss 20 %, and greatly improve production efficiency and reduce energy consumption.

Breakthrough progress has been made in product variety and quality. At present, there are hundreds and dozens of forged aluminum alloys developed in the world, which can produce different alloys, different states, different properties, different functions and various shapes in large quantities. There are more than ten large-scale enterprises with various specifications and various uses of aluminum alloy forgings with a scale of over 30,000 t/a. At present, the world's aluminum alloy die forgings have a maximum projection area of ​​5M2, the longest aluminum forgings can reach 15M, the heaviest aluminum forgings up to 1.5t, and the largest forged ring diameters up to 7.5M, which can fully satisfy the largest aircraft. Spacecraft, rockets, missiles, satellites, ships, aircraft carriers, and power generation equipment, lifting equipment, etc. The internal organization, mechanical properties and dimensional accuracy of the product can also meet the requirements of various users, reaching a very high level in product development.

In recent years, countries around the world have not made much effort 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 lightweight aluminum forgings for transportation, and it is necessary to build new ones. A number of modern large and medium-sized aluminum forging production lines.

Foreign countries have also made great progress in the production of titanium forgings and high-temperature forgings, and have a fairly high level.

2. Analysis of domestic development status and level

Forging production has a long history in China. In the early days of the Yinxu culture more than 3,300 years ago, forging has been used for weapons production. Before liberation, forging production was very backward. After liberation, forging production has developed rapidly. Free forging hydraulic press below 125MN, die forging hydraulic press below 300MN, die forging hammer below 160KN, friction press below 1600KN, hot forging press below 80000KN have been equipped with various series. Forging plant. China has only 300 MN, 100 MN, 60 MN, 50 MN, 30 MN five large and medium-sized aluminum forging hydraulic presses and one 100 MN multi-directional molding hydraulic press. The annual production capacity is only about 10000 t/a, and the projected area of ​​the largest die forgings is 2 M2, 1.2 M2, the largest. The length is 7M, the maximum width is 3.5M, the maximum diameter of the forged ring is φ3.5M, and the aluminum alloy reel has a disk diameter of φ534 to φ730mm. The product variety is relatively small. For example, die forgings in industrial developed countries account for about 80% of all forgings, while China only accounts for about 26%. Computer design has been introduced in the design and mold manufacturing of foreign die forgings. The forging die CAD and forging process simulation have entered the practical stage, and many forging plants in China have just started in this respect. The level of automation and process technology of process equipment is also relatively backward.

According to the above analysis, at present, China's aluminum alloy forging industry is 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 are far from the advanced level of foreign countries. 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 pace of transportation lightweighting to replace steel forgings with aluminum forgings. To this end, China should concentrate manpower, material resources and financial resources, improve the level of process equipment and production technology of aluminum alloy forging production in China as soon as possible, and build a number of 60-500MN modern aluminum alloy forging hydraulic press production lines as soon as possible to narrow down with foreign countries as soon as possible. The gap in the advanced level will meet the needs of domestic and foreign markets to the utmost extent.

V. Basic conditions and favorable conditions of the contractor

Sixth, typical products and production scale

7. Production process and analysis of main technical processes

8. Main equipment and auxiliary equipment and supporting facilities

IX. Estimation and source of funds

X. Economic and technical analysis

XI, safety and environmental protection

Twelve, plane distribution

Note: Chapters 5 to 12 are discussed in detail in the feasibility analysis report.