新的防腐蚀材料承载构件制作文档格式.docx
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每提高一个百分点就意味着可节约10万t钢材。
我国机械工业的铸、锻件综合废品率偏高,造成原材料和能源的浪费,有人调查过部分企业,铸铁件废品率为12%~14%,铸钢件废品率为10%~11%,有些厂甚至高达20%,而国外一般低于5%。
Accordingtostatistics,therateisabout60%theuseofmechanicalindustryofsteelproductsinChina,comparedwithdevelopedcountries,thereare10%~15%gap.Foreveryincreaseofonepercentagepointwouldmeansavingsof100000tsteel.China'
smachineryindustrycasting,forgingcomprehensivehighscraprate,causingrawmaterialsandenergywaste,hasinvestigatedsomeenterprises,castironscraprateis12%~14%,steelscraprateis10%~11%,someevenashighas20%,whiletheforeigngenerallylowerthan5%.
二、机械工程中节材的途径
Methodsmaterialstwo,mechanicalengineering.
机械工业节约材料的重点是钢材等金属材料,同时也要注意节约其它原材料。
从技术经济角度来看,机械工业节材必须考虑以下四个方面:
降低产品的材料消耗;
减少制造过程中的材料消耗量;
提高产品质量;
延长产品规定的服役期间。
Savematerialmainlymachineryindustryissteelandothermetalmaterials,alsowanttopayattentiontosavetheotherrawmaterials.Fromthepointofviewoftechnologyandeconomy,industrialmachinerymaterialmustconsiderthefollowingfouraspects:
toreducetheconsumptionofmaterialproducts;
reducethemanufacturingprocessofthematerialconsumption;
improvethequalityoftheproducts;
servedduringtheextendedproductregulations.
(一)采用先进技术,提高利用率
(a)theuseofadvancedtechnology,improvetheutilizationrateof
采用先进制造技术,提高铸件精度,推广精密性成形技术,在金属件生产中扩大中精锻件比例,使模锻、精锻件比例提高到60%以上;
继续推行集中下料、科学套材、改进下料工艺和装备,推广各种精密,自动、数控编排的切割技术,采用带锯床、中温剪切等下料新设备;
大力采用先进焊接技术,减少焊条用量;
采用先进的热处理技术,提高零部件寿命;
推广可控气氛,少、无氧化热处理工艺和锻造用保护气氛加热工艺和装备,减少金属氧化损失;
吊车采用材料表面处理技术,提高材料表面性能,实现节材低耗;
对于关键基础体(轴承、齿轮、弹簧、液压气动元件、模具等),扩大采用精炼钢和脱氧钢,以及行之有效的热处理和表面热处理新技术,显著延长其使用寿命。
Theuseofadvancedmanufacturingtechnology,toimprovetheprecisionofcasting,precisionformingtechnologypromotion,expandtheproportionofforgingsinmetalpartsproduction,theforging,precisionforgingratioincreasedtomorethan60%;
continuetoimplementcentralizedblanking,ScienceKit,improvementofblankingprocessandequipment,promotionofvariousprecision,cuttingtechnology,NCautomaticarrangement,thebandsawingmachine,warmshearcuttingequipment;
toadoptadvancedweldingtechnology,reducingelectrodeconsumption;
heattreatmentwithadvancedtechnology,improvetheservicelifeofcomponents;
popularizingcontrolledatmosphere,little,nooxidationheattreatmentandforgingwithprotectiveatmosphereheatingtechnologyandequipment,reducetheoxidationofthemetallossbymaterials;
surfacetreatmenttechnology,toimprovethesurfacepropertiesofmaterials,toachievematerialconsumption;
forthekeybasebody(bearings,gears,springs,hydraulicpneumaticcomponents,moldandsoon),toexpandtheuseofrefinedsteelanddeoxidizedsteel,aswellaseffectiveheattreatmentandsurfaceheattreatmenttechnology,prolongitsservicelife.
(二)采用先进的防腐蚀技术,提高设备的使用寿命
(two)useofadvancedanti-corrosiontechnology,improvetheservicelifeoftheequipment
在国民经济中不论哪个部门都毫无例外的存在着腐蚀问题。
腐蚀给人们造成的危害也是很大的,它一方面造成设备、塑料土工格栅零件等材料的直接损失,另一方面还造成影响正常生产,恶化操作环境,影响产品质量,新工艺不能上马,设计上的保守,以及发生人身安全事故等一系列重大的损失。
由此可见,腐蚀是自然界最大浪费之一。
因此,防腐蚀也是机械工程中节材的又一重大技术课题之一。
随着科学技术的飞速发展,新的防腐蚀材料和方法的不断涌现中防腐蚀技术也在不断提高。
Inthenationaleconomy,regardlessofwhichdepartmentarenoexceptionsexistcorrosionproblems.Damagetopeoplecausedbycorrosionisgreat,ithascauseddirectlossofequipment,partsandothermaterials,ontheotherhandalsoaffectthenormalproduction,thedeteriorationoftheoperationalenvironment,affectingthequalityofproducts,thenewtechnologycannotstart,theconservativedesign,aswellasthepersonalsafetyaccidentandaseriesofsignificantlosses.Therefore,thecorrosionisoneofthebiggestwasteofnature.Therefore,oneofthemajortechnicalproblemsandpreventmaterialcorrosionandmechanicalengineering.Withtherapiddevelopmentofscienceandtechnology,butalsointhecontinuousimprovementofcorrosionprotectiontechnologiescontinuetoemergeanticorrosionmaterialsandmethodsinnew.
(三)扩大应用新材料,改善用材结构
(three)toexpandtheapplicationofnewmaterials,improvementoftimberstructure
扩大应用新材料,改善用材结构,提高用材水平,积极推广各种高强度低合金钢、冷成形钢、冷拔钢管等高效钢,使用切削钢、新型模具钢、感应淬火钢等节能节材新材料;
扩大硬质合金材料的使用,以及节约高速钢和模具钢等t扩大粉末冶金材料在汽车、拖拉机和家用电器等方面的应用;
在汽车、农机和交通运输设备中,开发应用工程塑料和复合材料。
比如用高强度低合金钢代替普通碳钢制作一般承载构件,可以减少重量10%~30%。
Toexpandtheapplicationofnewmaterials,improvethetimberstructure,improvethemateriallevel,activelypromoteavarietyofhighstrengthlowalloysteel,coldformingsteel,cold-drawnsteeltubeandhighXiaogang,usecuttingsteel,steel,inductionquenchingsteelmaterialsavingnewmaterial;
expandtheuseofhardalloymaterial,andsavingofhighspeedsteelanddiesteelttoexpandtheapplicationofpowdermetallurgymaterialsinautomobile,tractorandhouseholdappliances;
inautomobile,agriculturalmachineryandtransportationequipment,developmentandapplicationofengineeringplasticsandcompositematerials.Suchastheuseofhighstrengthlowalloysteelinsteadofcommoncarbonsteelmakingbearingcomponents,canreducetheweightof10%~30%.
20世纪90年代初以来,国内的一些部门对修复热处理已经作了尝试工作,如对长期服役过的发电设备上的某些重要零件进行修复热处理。
应用等离子喷涂技术对重载坦克车辆零件进行再制造修复和强化,实车考核证明用再制造技术修复和强化的零部件比新品的相对耐磨性提高1.9~8.3倍,寿命提高2~3倍。
对首钢从比利时购进的二手连铸设备中的三百多件大型轴承座和轧辊,经再制造修复后,已使用数年。
目前一些单位已经开始汽车、计算机、空调、电冰箱、摩托车等产品零部件再制造的研究工作。
再制造工程技术不仅能恢复原产品的技术性能,还能及时引进新技术、新工艺和新材料,改进提高产品的技术性能和可靠性,从而延长了产品的使用寿命。
再制造产品的费用仅为新品价格40%~60%,达到了废物利用,变废为宝的目的,为降低材料消耗,节约原材料开辟了一条新的途径。
Sincetheearlynineteenninties,somedomesticsectorsofrestorationheattreatmenthasbeentryingtoworkonsomeimportantparts,suchaspowergenerationequipmenthaslongservedtherestorationheattreatment.Technologyofremanufacturingrepairandstrengtheningofheavytankvehiclepartsbyplasmaspraying,therealvehicletestprovedthattheremanufacturingtechnologytorepairandstrengthenthepartsthantherelativewearresistanceproductsincreasedby1.9~8.3times,lifeisincreased2~3times.OnthesecondarycastingequipmentShougangfromBelgiumpurchasedinmorethan300largebearingandroller,theremanufacturingrepair,hasbeeninuseforseveralyears.Thepresentresearchworkofsomeunitshavebeguntoautomobile,computer,airconditioning,freezer,motorcyclepartsmanufacturing.Thetechnicalperformanceandmanufacturingengineeringtechnologycannotonlyrecovertheoriginalproducts,butalsothetimelyintroductionofnewtechnologies,newprocessesandnewmaterials,improveproducttechnicalperformanceandreliability,therebyprolongingtheservicelifeoftheproduct.Productremanufacturingcostisonlythenewpriceof40%~60%,reachedthewasteutilization,thepurposeofturningwasteintotreasure,inordertoreducematerialconsumption,savingrawmaterialshasopenedupanewway.
提高产品设计水平,充分发挥材料潜力,降低材料消耗以轻量化为目标,大力推广计算机辅助设计,优化设计,有限寿命设计、防腐蚀设计和价值工程方法,使产品既可靠安全又结构紧凑,用材合理;
适当提高材料使用强度等级,充分发挥材料性能潜力,降低材料消耗。
Improvethelevelofproductdesign,givefullplaytothepotentialofmaterials,reducethematerialconsumptiontolightasthegoal,andvigorouslypromotethecomputeraideddesign,optimizationdesign,finitelifedesignmethod,anticorrosiondesignandvalueengineering,theproductissafeandreliableandcompactstructure,reasonableusewood;
appropriateincreaseofmaterialstrength,givefullplaytothematerialpropertiespotential,reducetheconsumptionofmaterials.