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世界之最科技成果：世界上公稱(chēng)擠壓力最大(225MN)的鋁擠壓機

——2023年重型機械世界之最科技成果獲獎項目專(zhuān)題報道

設備/技術(shù)名稱(chēng)：25MN臥式鋁擠壓成套裝備關(guān)鍵技術(shù)研發(fā)及應用

研制單位：太原重工股份有限公司 www.tyhi.com.cn，太重（天津）濱海重型機械有限公司

首次投運時(shí)間：2017.11

聯(lián)系人：王曉磊，17694972845 

本項目屬于工業(yè)制造領(lǐng)域有色金屬成型行業(yè)的超大重型成套裝備，其生產(chǎn)的鋁合金型材被廣泛應用于航空、航天、艦船、高鐵等國防和重大新興工業(yè)領(lǐng)域，尤其是薄壁、寬幅、高精度、截面復雜的超大規格鋁合金型材，對上述領(lǐng)域的輕量化、高速化發(fā)展具有戰略支撐作用。

本項目創(chuàng )新成果整體達到國際先進(jìn)水平，其中大中型擠壓機“疊板張力柱式全預緊封閉框架” 設計計算方法及制造安裝技術(shù)達到了國際領(lǐng)先水平：首次提出雙勾頭、雙半圓鍵傳力結構和預張緊加工技術(shù)，張力柱應力高值降幅達70%，加工量減少90%，加工期縮短60%，突破了張力柱長(cháng)期制約框架承載能力的瓶頸。

本項目共授權專(zhuān)利24項，推動(dòng)了我國重型鋁擠壓加工裝備研制水平的整體提升。項目產(chǎn)品累計銷(xiāo)售4臺套，首套“225MN臥式鋁擠壓成套裝備”成功應用于遼寧忠旺鋁擠壓加工基地項目，經(jīng)濟和社會(huì )效益顯著(zhù)。為實(shí)現高端超大規格工業(yè)鋁型國產(chǎn)化、服務(wù)重大戰略產(chǎn)業(yè)的輕量化發(fā)展、提升中國高端裝備的全球競爭力奠定了重要基礎。 

圖1：225MN鋁擠壓成套裝備由擠壓機前設備、擠壓機主機和成品后處理設備組成，擠壓機前設備主要用于模具加熱，坯錠加熱、潤滑、輸送等；擠壓機主機作為鋁擠壓成套裝備的核心，負責完成制品的擠壓成形；成品后處理設備主要用于對擠壓制品進(jìn)行淬火、牽引、橫向轉移、拉扭矯直及定尺鋸切等。

圖2：225MN鋁擠壓生產(chǎn)線(xiàn)所擠壓型材最大外接圓可達φ800mm，此圖中擠制產(chǎn)品為電機外殼，合金6063-T6，主要應用于輕量化交通運輸領(lǐng)域。

圖3：傳統沖鋒艦船體采用耐海水腐蝕性好的5系鋁型材拼焊而成，單件最大寬度約0.5m，焊縫較多，焊縫易受海水腐蝕，滲漏幾率大，嚴重影響艦船使用安全性；采用225MN鋁擠壓機，通過(guò)先擠制帶筋圓筒再切割寬展的方式，展幅可達1690mm，綜合焊縫減少60%，降低了滲漏幾率，極大提升了艦船的使用安全性和壽命。

The world's largest aluminum extrusion press in terms of nominal extrusion pressure

Research and Development on Key Technology and Its Application of The 225MN Horizontal Aluminum Extrusion Complete Equipment

Taiyuan Heavy Industry CO.,LTD, www.tyhi.com.cn

TZ(Tianjin)Binhai Heavy Machinery CO.,LTD

This project, the oversized and heavy sets of equipment, belongs to the non-ferrous metal forming industry in the field of industrial manufacturing, and the aluminum alloy profiles it produces are widely used in the fields of national defense and major emerging industries such as aviation, aerospace, ships, high-speed railways, etc. In particular, the oversized aluminum alloy profiles with thin-walled, wide-width, high-precision and complex cross-section are of strategic support to the development of the above fields in terms of lightweighting and high-speed development.

The innovative achievements of this project have reached the international advanced level as a whole, among which the design calculation method and manufacturing and installation technology of " Fully Pre-tensioned Closed Frame with Laminated Plate Tension Column" for large and medium-sized extrusion presses have reached the leading level in the world: it is the first time to put forward double hooks, double semi-circular key force transmitting structure and pre-tensioning processing technology, and the high value of the tension column stress has been reduced up to 70%, and the processing quantity has been reduced by 90%, the processing period has been shortened by 60%, and it breaks through the bottleneck of the long-time constraints on the frame load-bearing capacity of the tension column.

A total of 24 patents have been authorized for this project, which has promoted the overall improvement of the development level of heavy-duty aluminum extrusion equipment in China. Four sets of this project products have been sold, and the first set of "225MN horizontal aluminum extrusion equipment" has been successfully applied in Liaoning Zhongwang Aluminum Extrusion and Processing Base Project, with remarkable economic and social benefits. The project has laid an important foundation for realizing the localization of high-end oversized industrial aluminum, serving the lightweight development of major strategic industries, and enhancing the global competitiveness of China's high-end equipment.