2011-3-11 8:54:34PRINT
Report of China International Forgemasters Meeting 2010 (CIFM2010)
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China International Forgemasters Meeting 2010 (CIFM2010), ended on 27th May 2010 in Shangri_La Hotel, Chengdu, Sichuan Province, China. There are nearly 380 delegates from 17 countries attending this meeting, in which more than 110 delegates come from 50 foreign companies.
China International Forgemasters Meeting (CIFM) is held biyearly. Focusing on “Get to Know China”, CIFM2010 is composed of meeting and on-site exposition.
In the meeting, the Chinese famous forgemasters have been invited by Organizing Secretariat to introduce their latest development. Meanwhile, 35 papers were selected from over 50 papers submitted by delegates were introduced during the meeting, which 15 papers were from 8 foreign countries such as Germany, Italy, USA. Besides the presentation, a plant tour to China National Erzhong Group Co. has been arranged for registered delegates.
33 enterprises took part in the on-site exposition being simultaneous with the meeting. Many famous international equipment and facility suppliers showed their advanced technologies in the exposition.
More international communication activities will be held by Confederation of Chinese Metalforming Industry (CFMN) in the next years. After CIFM2010, 3RD ASIAFORGE MEETING will be held on 12th -16th Sept. 2010 in Renaissance Shanghai Zhongshan Park Hotel, Shanghai, China. (Please gain more information at http://www.chinaforge.com.cn/AFM2010/English
/index.asp).
China International Forgemasters Meeting 2012 (CIFM2012) will be held in 2012 in China. Two years are not a long period, but lots of changes will be happen to the Chinese open-die forging industry. We welcome you to come to know our latest development in 2012.
    Jin Zhang, Secretary General of CCMI Mulin Han, Deputy Secretary General of
CCMI
Please take a look at details of CIFM2010 by as follow:
MEETING AGENDA
Present Situation and Development of Open-Die Forging Industry in India
Sivaprasad Reddy Rachamallu (Association of Indian Forging Industry [AIFI], India) ABSTRACT: Indian Open - die forging industry is going to transform into a high tech & hi - profile industry with government of India’s plan to substantially increase the power generation capacity to meet the ever growing demand for electrical power within the country during the next decade. Even during the time of recession all over the world, new manufacturing plants for producing power plant equipment are established in India to meet requirements of Wind, Nuclear, Hydel and Thermal power generation industry. Top Indian corporate giants and public sector companies are creating / adding new facilities in a big way to cast Steel ingots up to 200 Ton and supply Open-die forgings for this sector.
Development of Open-Die Forging Industry in China
Wang Shu (China National Erzhong Group Co., China) ABSTRACT: Heavy forgings and castings manufacturing industry is very special that not only the key industry for national economic construction and development, but also the foundation of heavy mechanical industry and necessary and strategic industry for national defense and economy. The author introduces developing trend of heavy forgings and castings manufacturing industry all over the world, as well as the latest development of the Chinese open-die forging industry.
Recent Development at Open-die Forging equipments in the world market
Mr. Serdar Tuncel (SMS Meer GmbH, Germany) ABSTRACT:
RESEARCH AND DEVELOPMENT REFERENCE ON LARGE FREE FORGING OF CFHI
Zhou Xiaoping (China First Heavy Industries Co., China) RESEARCH AND DEVELOPMENT ON LARGE-SIZED FORGINGS OF CHINA ERZHONG
Sun Haiyan (China National Erzhong Group Co., China) INTRODUCTION OF SHANGHAI HEAVY MACHINERY PLANT
Ma Mingfang (Shanghai Heavy-Duty Machinery Factory Co., Ltd., China) RELYING ON EQUIPMENT AND INNOVATING TECHNOLOGY-TO PROMOTE THE RAPID DEVELOPMENT OF ENTERPRISE
Shi Yulin (CITIC Heavy Industries Co., Ltd., China) Improving administration of enterprise by means of ERP
Zhang Ruiqing (Asia Advance Forgings PTE. LTD, China) A SUMMARY FOR THE PRODUCT TECHNOLOGY AND PROCESS INNOVATION, ACHIEVEMENTS OF HEAVY FORGINGS FROM TONGYU HEAVY INDUSTRY
Wang Shizhen (Shandong Tongyu Group Co., Ltd., China)
A Brief Analysis Of Metallurgical Processes Of High-quality Special Steel For Forging
Li Guozhong (CITIC Pacific Special Steel Holdings, China) ABSTRACT: Special steel for forging should have conmbination property requirements on good internal and surface quality, good hardenability, homogeneous chemical composition and structure, small deformation of heat treatment, good impact toughness etc.. Over the years, along with the progress of metallurgical processes of special steel, special steel manufacturers have already been capable of producing high quality special steel for forging by using various advanced steel-making and rolling technology. Special steel manufacturers are more closely combined with forging manufacturers.
Clean Steel Technology
Zhu Yanguo (Timken（China) Investment Co., Ltd.) ABSTRACT:
New Plant Concepts for the Production of Large Size ESR Ingots
H. Holzgruber, A. Scheriau, B. Rinnerhofer (INTECO Special Melting Technologies, Austria) Abstract: A massive demand for ESR ingots up to 250 metric tons has evolved, especially for end use in the power generation industry. The three large sized ESR furnaces which are currently engineered by INTECO are either static mold furnaces or combined furnaces, using both static mold and short collar mold remelting. Electrode change technology is applied for the production of large ingots, in both types of melt stations. The plant concepts, dimensions as well as electrode and ingot configurations of the three mentioned plants are discussed, focusing on the following aspects. Possible types of power supplies as well as their advantages and disadvantages are discussed. The influence of the high current line design on the plant‘s overall resistance and reactance and special aspects concerning the control system are indicated. The mechanical design, which is done using a 3D CAD system, is verified by FEM simulations. The results of ESR process simulation, along with empirical data from existing furnaces, are the basis for the design of the cooling water system. Briefly, the current conductive mold (CCM®), which is used for remelting of segregation prone alloys in short collar mold melt stations, is described.
Ten times speed of band saw cutting
TOKIWA, Toru (AMADA Co., Ltd., Japan) ABSTRACT: Today, there are increasing demands for large, high-strength, lightweight, or heat-resistant materials in the industry. This suggests that, when we cut the materials, we have to deal with large and hard-to-cut materials more than ever. The band-shape of a blade frequently triggers vibration due to fluctuation in cutting resistance, and this vibration progresses to Friction-type vibration accompanied by extremely high noise. This has been a major problem that obstructs improvement of cutting performance. As it is caused by property of the blade itself, it has been very difficult to solve the fundamental problem since band saw machines came into practical use. Recently, Amada devised Pulse Cutting Technology for band saw machine and developed new Carbide Tipped Band Saw Blade called AXCELA . These two technologies have enabled us to cut the hard-to-cut materials such as titanium alloys at ten times speed of cutting compared to conventional methods.
Dimensional Measurement System on Large Open Die Forgings
Riccardo Bianchi (Tecnogamma / MERMEC Group, Italy) ABSTRACT: In the forging sector, the problem of dimensional check is of considerable importance due to quantitative aspects, but also to reduce the quantity of metal used. Currently, dimensional controls are carried out in a manual way with barely reliable results using low-precision instruments. TECNOGAMMA S.p.a has designed two systems, ―TOPSCAN‖ and ―CLOUDSCAN‖, based on laser-camera triangulation systems and phase shift ranging, to acquire accurate measures of large, hot pieces during forging phase and to automatically provide dimensional checks. Both systems are fully automatic and are based on remote measuring, which improves safety. Both systems guarantee more complete and accurate measurements than the traditional manual systems.
This is it-The Most Powerful and Most Modern Open Die Forging Plant
Wang Chun Ming (CITIC Heavy Industries Co., LTD., China) Michael Pahnke (Wepuko-Pahnke, Germany) Rainer Dango, Stefan Krusch, Michael Orthey (Dango & Dienenthal, Germany) ABSTRACT: An open die forging press with a maximum forging force of 165 MN (16500 t) for bar and shape forging and an upset force of 185 MN for concentric forging is going to be the strongest press of this type. The press will be matched with a rail-bound forging manipulator of 2500 kN lifting force and 7500 kNm carrying capacity, also unmatched by any other existing forging manipulator. Together with a strong oil-hydraulic PMSD drive of nearly 12 MW installed electric power this will be the most powerful open die forging plant in the world.
Vibration and Shock Isolation Systems for Forging Hammers and Presses
Keith Leatherwood (Vibro/Dynamics Corporation, U.S.A)
Research on Forging Method of Large Cone-shaped Cylinder
Hu Chaobei, Zhang Guogang, Sunfeng, Ma Mingfang (Shanghai Heavy-Duty Machinery Factory Co., Ltd.) Abstract： In order to solve a large cone-shaped cylinder forging technical problems, the Shanghai Heavy Machinery Plant in the drawing based on the experience at home and abroad carried out trials and studies, and successfully forged out of a big-diameter Φ6160mm, Small End Diameter Φ4430mm, high 3470mm cone-shaped cylinder. This principle of the class cylinder forging, finite element analysis software MARC simulation, forging process and in-kind forging process is analyzed and summarized.
Gap-Temperature Method For Flake Elimination in Forgings
Fu Qianjin, Zhang Weishan, Fu Qiang, He Zhanwei (Dalian Huarui Heavy Forging and Casting Co. Ltd., China) Abstract: Among large size forgings, the mushroom shape ones by upsetting are easy to form, however, they are not only hard to control the direction of inside fiber but also difficult to repair flake defect founded under UT Exam. This paper mainly introduces the utilization of gap-temperature method under such circumstances.
Research on Control Technology of Cracks in Heavy Open-Die Forging
Han Jingtao (University of Science & Technology Beijing, China) Abstract: To solve the Inner-crack problem of the disk-shaped forgings, control pre-upsetting deformation and single pass reduction, belling as well as crack healing through heating and holding technologies is proposed. Flow control casting, reverse squeezing with a flaw millstone, heavy reduction with wide flat anvil and crack healing through heating and holding processed is used in the axial forging production. The technic mentioned above solve the inner-crack problem of the disk-shaped and axial forgings, which improves the quality and useful time of the heavy forgings, increases the qualification rate by a large margin and brings remarkable economic benefits.
Development of Manufacture of Generator Retaining Ring Forgings
Guo Huiguang (Taiyuan University of Secience and Technology, China) Abstract：Many achievements in scientific and technological innovation, investigation and development, productive progress and so on have been represented briefly in this paper. It concerns the key procedures such as raw material choice, process scheme, blank-making by hot deformation and strengthening of manufacturing techniques for generator retaining rings. And it has been introduced that the key point of short-route hot forging process for heavy retaining rings, key technologies of blank-making by hot deformation and the technique scheme of hydraulic bulging strengthening. It emphasizes briefly on analysis and prospect about the significance of controlling hot-deformation process, scientific investigation of blank-making during hot-deformation process，research and application of the hydraulic bulging strengthening method.
Development of Marine Diesel Engine Crankshaft Forgings
Hu Chaobei, Sunfeng, Zhang Guogang, Ma Mingfang (Shanghai Heavy-Duty Machinery Factory Co., Ltd.) Abstract：Marine Crankshaft is the sustainable development of China''s shipbuilding industry bottlenecks. Shanghai Heavy Machinery Plant Co., Ltd. has successfully developed large heavy marine crankshaft forgings. This paper introduces marine crankshaft forgings forging processes, forging production using computer simulation to solve the defects and optimize the process and standardize the process of forging operation.
New Possibilities to Improve Heavy Forging Ingots Quality
Lev Medovar (E.O.Paton Electric Welding Institute, Ukraine) Latest Developments in the Mechanized UT Inspection of Big Forgings
Klaus Leupoldt, Heinz-Josef Otte, Willibald Meister (Cegelec NDS, Germany) ABSTRACT
Since more than 40 years Cegelec NDS (formerly MAN) as part of the multi-national Cegelec Non-destructive Testing (CNDT) is active as mechanized NDT service provider in the energy and transportation business. Inspection systems for this kind of application are developed in-house and provided to the market.
For the mechanized inspection of turbine / generator rotors and disks the inspection systems TURO-MAN and SIRO-MAN have been developed by Cegelec and are sold world-wide. In cooperation with our customers, acceptance of mechanized inspections using TURO-MAN and SIRO-MAN were achieved with all major turbine manufacturers (ALSTOM, GE, Siemens etc.)
TURO-MAN and SIRO-MAN are equipped with UT electronic equipment provided by Olympus NDT. For conventional UT applications MS5800 and for Phased Array applications FocusLT are used.
TURO-MAN - systems have been delivered for rotors up to a length of 20 m, diameter 3.5 m and weight of 400 tons. SIRO-MAN system maximum capacity delivered to date is diameter of 3.5m, height 4.5 m and a weight of 100 tons.
Other systems are offered for the inspection turbine central bore, generator retaining rings, bars and plates for aircraft industry and wheel set axles of trains.
Multi-station flexible forging system
Liu Linzhi (Tianjin Tianduan Press Co., Ltd., China) ABSTRACT: This paper introduces a new type of equipment for upsetting and piercing large forging parts. The whole procedure realizes mechanical and automatic control. The design of this equipment results in a compact link of upsetting station, pre-piercing and final-piercing stations by adopting double-work station machine body structure. Through double-station moving worktable, the work piece can be moved fast among the 4 work stations, ensuring the need of transition among stations. The fast centering device always keeps the piercing accuracy.
Competitive Forging of Rings
Klaus- Andreas Kienle, Lei Jiakun (Schuler, Germany) Manipulators with Mass Division Increase Throughput and Save Energy
W. Nowitzki (Glama Maschinenbau GmbH Gladbeck，Germany) Xue Dingyuan (Gibo GmbH China, China)
Modern Mechanical Design and Automation System in the Forging Process
Gianetti Franco, Wang David Shuyu (Danieli & C Officine Meccaniche S.p.A., Italy) An Analysis on Technical Economic Effects of Modern Open-Die Forging Hydraulic Press—Development Tendency of Open-Die Forging Hydraulic Press Observed from Ecomomic Effects of Forging Production
Guo yuxi (Taiyuan Heavy Industry Co., Ltd. China) Abstract：In this text it has, starting from economic point of view of forging production, discussed and analyzed superficially to modern open-die forging hydraulic press-technical performance, economic effect satisfaction, and its development direction of the open-die forging hydraulic press and its complete equipment with oil pump direct drive, double-column-oblique-placement pre-stressed frame. It is beneficial to the economic development of the forging industry towards energy saving, material saving, consumption lowering, exhaust reduction, and low carbon, and to the improvement of overall technical level of forging production in China.
30MW Hydraulic Drive for a New 360MN Steel Pipe Extrusion Press Plant
Michael Pahnke (Wepuko Hydraulik, Metzingen, Germany) Wu RenDong (TsingHua University Beijing, China) Lei, BingWang, Bai Zhen (NORHEINCO, China) New Type of Full Hydraulic Free Forging Hammers
HU Da-yong, XIA De-shi (Beijing Ningyuan Xingda Technology Development Co., Ltd., China) Abstract: As the important equipment in forging field in China, forging hammer has been improved by electro-hydraulic technology. The working principles of the whole system and controlling valves of the hydro-pneumatic hammer, driven by single hammer rod with oil discharge and liquid filling, are introduced in this paper. The shortcomings of the designing principle and structure of the hammer, including gas-oil crossing, heating from valves leakage, unexpected hammering phenomenon and hydraulic impact are analyzed. The working principles and the advantage of the full hydraulic electro-hydraulic hammer are also introduced in this paper. The practice shows that the full hydraulic electro-hydraulic hammer can meet the process requirement for both die forging hammers and free forging hammers, and overcome the shortcomings of the hydro-pneumatic hammer completely. It is the inevitable upgrade product as the hydro-pneumatic hammer.
Phased Array Technology for the Inspection of Large Forgings for the Nuclear and Power Generation Markets
_____________ (IntelligeNDT Systems & Services GmbH, Germany) ABSTRACT: IntelligeNDT Systems & Services GmbH (iNDT) is a subsidiary of AREVA specialized in mechanized non-destructive testing systems and services, in particular in the nuclear power generation industry and the steel and forgings industries.
Forging Technology with High Efficiency for Tube by Hydraulic Presses
Nirolayp. Petrov (OAO Tyazhpressmash, Russia) Hydraulic Drive&Control of High Speed Open Die Forging Special Alloy Production
Chris Howie (Oilgear International Corporation, U.S.A ) ABSTRACT: Forging of Titanium and high strength Super Alloy Nickel is characterized by a number of factors that make forging t these materials more difficult than steel forging..
Titanium forging , and certain super alloys, must be done within specific Temperature Range and Forge Tonnage characteristics. These conditions dictate that Forge Press and Manipulator performance must operate at certain key high performance criteria to be able to produce high quality forge product. This paper will illustrate Key Press and Manipulator Specifications applicable to popular size of 45/55Mn and 65/80 Mn Press Size(s).
Design and Selection of Forging Hammer Vibration Control System
J. E. Chen (Guang Zhou An Gle Vibration Control Co. Ltd., China) Abstract：In this paper, the differential equation of forging hammer vibration was established first. Then, the hammer shift and impacting force on the foundation were introduced. And next, the hammer maximal shift and the force of the calculation equations were deduced with the mathematic maximal principle. According to the type and technical process of the hammer, the maximal hammer shift limit could be set, which can determine whether forging hammer machine is directly installed on a spring elements damping vibration isolator. If the hammer shift exceeds the limit, an additional mass quantity can be calculated to control the hammer shift within the maximal limit.
Development of Equipment for Small&Medium Sized Open Die Forging
____________ (Qingdao Huadong Engineering Machinery Co., Ltd.) On-Site Exposition
There are 33 enterprises taking part in the On-Site Exposition. They are as follow:
China Metalforming Equipment & Manufacturing Technology (CMET)
JIANGSU HONGCHENG FORGING AND PRESS MACHINE CO. LTD.
Wenzhou Ruili Saw Co., Ltd.
Xinzhou Wutaishan Forging Equipment Plant of Shanxi Province
Zhongye Jincheng (Yingkou) Equipment & Technology Co., Ltd.
Chongqing Diyi Heavy Forging Co.,Ltd.
SINON Combustion Equipment Co., Ltd.
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