Steel wire winding combined type lightweight structure for core part of ultra-large screw press

Abstract

According to the core part steel wire winding combined light-weight structure of the ultra-large screw press, each memorial archway of a double-memorial-archway steel wire winding machine body is formed by splicing nine blocks, and the double-memorial-archway steel wire winding machine bodies are fixed by applying pre-tightening force through super nuts to form the whole machine body; the upper cross beam part, the movable cross beam part and the lower cross beam part are all formed by splicing four blocks and then winding and combining the four blocks with ultrahigh-strength steel wires made of 65Mn and other materials with the yield strength of about 2000MPa, and the weight and the size of each block are only about one fourth of those of an original overall structure; in order to solve the manufacturing problem of core parts of the ultra-large screw press with the maximum cold striking force reaching tens of thousands of tons, the invention effectively solves the problem that the weight of a single part of the ultra-large screw press is hundreds of tons by winding and combining ultra-high-strength 65Mn steel wires with the yield strength reaching about 2000MPa after the ultra-large screw press is disassembled; the manufacturing and transportation difficulty of the ZG20SiMn material casting with the yield strength of about 300-350 MPa and even thousands of tons is lowered, and light weight is achieved.

Description

Technical Field

[0001] This invention belongs to the technical field of spiral presses in forging equipment, and specifically relates to a lightweight structure of steel wire winding combination for the core component of an ultra-large spiral press. Background Technology

[0002] A screw press is a forging device that converts the kinetic energy of a flywheel rotation into a tremendous impact force. Its core principle lies in driving the flywheel to rotate at high speed to store energy, and then converting the flywheel's rotational motion into the linear motion of a slider through a transmission system, thereby releasing high-energy impact force instantaneously and causing plastic deformation of the workpiece. Industrially used screw presses in the forging field are mainly divided into friction type, electric type, hydraulic type, and clutch type. Ultra-large screw presses with maximum cold impact forces of tens of thousands of tons generally adopt a clutch-type transmission scheme. For example, SMS Group's world's largest tonnage 355MN and 365MN screw presses with the highest cold impact forces are both clutch-type screw presses. This is mainly because clutch-type screw presses break the fixed cycle of the traditional screw press flywheel's "forward rotation for energy storage - reverse rotation for return." Its core design lies in adding a clutch control system between the continuously rotating energy-storing flywheel and the screw driving the slider. This structure separates "flywheel idling energy storage" from "screw on-demand drive": during operation, the clutch engages instantaneously, transferring the kinetic energy stored in the flywheel to the screw to complete the strike; after the strike, the clutch disengages quickly, and the flywheel can continue to maintain its speed for return use.

[0003] However, the aforementioned clutch-type screw press has a total weight of nearly 3,000 tons. Each of the four core components—the machine body, upper crossbeam, movable crossbeam (main slide), and lower crossbeam (base)—weighs about 800 tons. If castings made of ZG20SiMn material with a yield strength of about 300~350MPa are used, the manufacturing process will be extremely difficult, and the installation and transportation after manufacturing will be very difficult and costly.

[0004] For example, the 365MN clutch-type screw press is nearly 20 meters high, and manufacturing the integral cast body using a one-time casting process is extremely difficult. Furthermore, the machine body, consisting of an upper crossbeam, columns, and a lower crossbeam (base and worktable), is pre-tightened by four tie rods with a diameter of nearly 1 meter. The yield strength of these four 1-meter tie rods made of medium carbon steel is only about 500 MPa at most, and the tie rods themselves are over 20 meters high, making manufacturing, transportation, and installation very difficult. Therefore, manufacturing each of the four core components of this ultra-large screw press—the machine body, upper crossbeam, movable crossbeam (main slide), and lower crossbeam (base and worktable)—weighing approximately 800 tons, has become a pressing problem.

[0005] The structure and manufacturing of core components for existing ultra-large screw presses with a maximum cold impact force of tens of thousands of tons face the following pressing challenges: The core components of these ultra-large screw presses, such as the machine body, upper crossbeam, movable crossbeam (main slide), and lower crossbeam (base, worktable), are too large and heavy when manufactured as a single unit, making them difficult or even impossible to manufacture. Large machine bodies and load-bearing castings pose significant transportation challenges in urban areas. Large castings are also prone to defects such as porosity and cracks within the material, leading to a decline in material properties. Considering these factors, to ensure the machine tool's load-bearing capacity and the strength and rigidity requirements of the machine body, the size and weight of the castings need to be increased. This would further enlarge the machine tool's size, further increasing manufacturing and transportation difficulties. Summary of the Invention

[0006] In order to overcome the shortcomings of the above-mentioned technologies, the purpose of this invention is to provide a lightweight structure for the core components of an ultra-large screw press, which is a steel wire winding combination. There are no parts that are too large or too heavy. While ensuring that each component of the machine tool meets the rigidity and strength requirements, it greatly reduces the difficulty of manufacturing and processing, reduces the difficulty and cost of transportation, and improves the casting performance of the castings.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A lightweight composite structure for the core components of an ultra-large screw press, using wire winding, includes a flywheel assembly 2, which is mounted on an upper crossbeam 5, which is installed between the double-arch steel wire winding machine body. A planetary roller screw pair engages with a clutch and a movable crossbeam 12, which is guided by a slide rail 20 mounted on a column 13 of the double-arch steel wire winding machine body. After the clutch engages, the movable crossbeam 12 moves downward and contacts the workpiece to complete the striking operation. The workpiece is mounted on a lower crossbeam 15, which is installed between the double-arch steel wire winding machine body. The double-archway wire winding machine body has two columns 13 on one side, with the upper and lower ends of the two columns 13 connected to a semi-circular beam respectively. Each semi-circular beam consists of two side crossbeam components 17 and a middle crossbeam component 16. Each column 13 consists of three column components. Each side archway machine body is pre-tensioned with wire winding to form a whole. The upper crossbeam 5 and lower crossbeam 15 installed between the double archway wire winding machine bodies are supported by support studs 18 and fixed with super nuts 19 on both sides with pre-tension, finally forming the whole machine body.

[0008] The upper crossbeam 5 includes four symmetrically arranged upper crossbeam sub-components 5-1. Each upper crossbeam sub-component 5-1 has a boss on its upper surface, a flange on its lower surface, and bosses on all four sides of the upper crossbeam. Pre-tensioned steel wire is wound in six directions around the entire structure, so that the four upper crossbeam sub-components 5-1 ultimately form a whole. The boss on the upper surface of the upper crossbeam is used to support the flywheel assembly. Through holes are machined in the fuselage direction to mate with the support studs 18. Semi-circular platforms are machined in the fuselage direction to mate with the semi-circular beams of the side arches. The flange on the lower surface serves to seal the transmission system.

[0009] The movable crossbeam 12 includes four symmetrically arranged movable crossbeam sub-components 12-1. Each movable crossbeam sub-component 12-1 forms a flange at the center of the axial direction. The upper and lower circular surfaces of the flange are wrapped with prestressed steel wire, so that the four movable crossbeam sub-components 12-1 form a whole. Guide blocks are installed at the four corners of the movable crossbeam 12 and connected by bolts. An adjustable slide rail 20 is installed on the machine body. The slide rail 20 cooperates with the guide blocks installed at the four corners of the movable crossbeam to guide the movable crossbeam 12.

[0010] The lower crossbeam 15 includes four symmetrically arranged lower crossbeam sub-components 15-1. Bosses are formed on six surfaces of the lower crossbeam 15 for prestressed steel wire winding, so that the four lower crossbeam sub-components 15-1 form a whole. The lower crossbeam 15 has through holes machined in the machine body direction to mate with the support studs 18; a semi-circular platform machined in the machine body direction to mate with the semi-circular beams of the side archways; and a through hole machined in the center of the lower crossbeam 15 in the vertical direction for the hydraulic ejection mechanism to remove the billet from the working pad.

[0011] The steel wire is made of a material with a yield strength of about 2000MPa and an ultra-high strength of 65Mn.

[0012] Compared with the prior art, the beneficial effects of the present invention are as follows: This invention ingeniously employs a segmented and wire-wound design for this ultra-large screw press. Each arch of its double-arch body is composed of twelve large sections, while core components such as the upper crossbeam, movable crossbeam, and lower crossbeam are each composed of four large sections. These sections are then wound together with steel wire made of ultra-high-strength 65Mn material with a yield strength of approximately 2000MPa. Each segment weighs and is only about one-quarter the size of the original overall structure. This invention achieves lightweight design, reduces the difficulty of component manufacturing, and minimizes transportation challenges. Attached Figure Description

[0013] Figure 1 This is a cross-sectional view of the overall structure of an embodiment of the present invention.

[0014] Figure 2 This is a left view of the overall structure of an embodiment of the present invention.

[0015] Figure 3 This is an attached view of the overall structure of an embodiment of the present invention.

[0016] Figure 4 This is a schematic diagram of the structure of the upper beam 5 in an embodiment of the present invention.

[0017] Figure 5 This is a schematic diagram of the structure of the movable crossbeam 12 in an embodiment of the present invention.

[0018] Figure 6 This is a schematic diagram of the structure of the crossbeam 15 in an embodiment of the present invention. Detailed Implementation

[0019] The present invention will now be described in detail with reference to the accompanying drawings.

[0020] Reference Figure 1 , Figure 2 , Figure 3 A lightweight composite structure for the core component of an ultra-large screw press, using wire winding, includes a flywheel assembly 2 connected to a rotary joint 1. The flywheel assembly 2 is mounted on an upper crossbeam 5 via an external toothed bearing. The upper crossbeam 5 is installed between the double-arch steel wire winding machine body. The flywheel assembly 2 and a pinion 3 form a gear pair. The pinion 3 is connected to a motor 4 via a key, and the motor 4 drives the flywheel assembly 2 via the pinion 3. The flywheel assembly 2 is connected to a main screw 11 via a spline. The main screw 11, rollers 10, nuts 9, cages 7, and internal gear rings 6 together form a planetary roller screw. The movable crossbeam 12 is guided by the slide rail 20 installed on the column 13 of the double-arch steel wire winding machine body. After the clutch is engaged, the movable crossbeam 12 moves downward and contacts the workpiece to complete the striking work. The workpiece is installed on the lower crossbeam working pad 14. The lower crossbeam 15 is installed between the double-arch steel wire winding machine bodies. The nut 9 is connected to the slider bushing 8 by bolts. The slider bushing 8 is connected to the movable crossbeam 12 by flanges and bolts. The working pad 14 is connected to the movable crossbeam 12 by bolts. Finally, the nut 9, slider bushing 8, movable crossbeam 12, and working pad 14 form a whole.

[0021] Reference Figure 2 , Figure 3 The double-archway steel wire winding machine body has two columns 13 on one side, with the upper and lower ends of the two columns 13 connected to a semi-circular beam respectively. Each semi-circular beam consists of two side crossbeam sub-components 17 and a middle crossbeam sub-component 16. Each column 13 consists of three column sub-components. Each side archway machine body consists of 12 sub-components, which are pre-tensioned and wound with steel wire to form a whole. The upper crossbeam 5 and lower crossbeam 15 installed between the double archway steel wire winding machine bodies are supported by support studs 18, and the two sides are fixed with super nuts 19 to apply pre-tension force, finally forming the whole machine body.

[0022] Reference Figure 1 The main screw 11 is mounted on the upper crossbeam 5 via a slewing bearing. The roller 10, the main screw 11, and the nut 9 form a helical pair. An internal gear ring 6 is mounted on the nut 9. The internal gear ring 6 and the end teeth of the roller 10 form a gear pair to ensure a stable transmission ratio during transmission. The cage 7 is mounted on both sides of the roller 10 to keep the relative circumferential position of the roller unchanged.

[0023] Reference Figure 4 The upper crossbeam 5 includes four symmetrically arranged upper crossbeam sub-components 5-1. Each upper crossbeam sub-component 5-1 has a boss on its upper surface, a flange on its lower surface, and bosses on all four sides of the upper crossbeam. Pre-tensioned steel wire is wound in six directions around the entire structure, so that the four upper crossbeam sub-components ultimately form a whole. The boss on the upper surface of the upper crossbeam is used to support the flywheel assembly 2. Through holes are machined in the direction of the machine body to cooperate with the support studs 18. Semi-circular platforms are machined in the direction of the machine body to cooperate with the semi-circular beams of the two side archways. The flange on the lower surface serves to seal the transmission system.

[0024] Reference Figure 5 The movable crossbeam 12 includes four symmetrically arranged movable crossbeam sub-components 12-1. Each movable crossbeam sub-component 12-1 has a flange formed in the axial center. The upper and lower circular surfaces of the flange are wrapped with prestressed steel wire, so that the four movable crossbeam sub-components 12-1 form a whole. Guide blocks are installed at the four corners of the movable crossbeam 12 and connected by bolts. An adjustable slide rail 20 is installed on the machine body. The slide rail 20 cooperates with the guide blocks installed at the four corners of the movable crossbeam to guide the movable crossbeam 12.

[0025] Reference Figure 6 The lower crossbeam 15 includes four symmetrically arranged lower crossbeam sub-components 15-1. Bosses are formed on six surfaces of the lower crossbeam 15 for prestressed steel wire winding, so that the four lower crossbeam sub-components 15-1 form a whole. The lower crossbeam 15 has through holes machined in the machine body direction to mate with the support studs 18; a semi-circular platform machined in the machine body direction to mate with the semi-circular beams of the side archways; and a through hole machined in the center of the lower crossbeam 15 in the vertical direction for the hydraulic ejection mechanism to remove the billet from the working pad 14.

[0026] The steel wire is made of a material with a yield strength of about 2000MPa and an ultra-high strength of 65Mn.

[0027] This embodiment of the ultra-large spiral press adopts a segmented and wire winding scheme. Its double-arch steel wire winding machine body, upper crossbeam, movable crossbeam and lower crossbeam are all assembled and combined with steel wires of ultra-high strength 65Mn and other materials with a yield strength of up to about 2000MPa. Each segment is relatively small in weight and size. This embodiment achieves lightweighting, easy component manufacturing, and easy transportation.

Claims

1. A lightweight structure for the core component of an ultra-large screw press, consisting of a steel wire winding assembly, comprising a flywheel assembly (2), characterized in that: The flywheel assembly (2) is installed on the upper crossbeam (5), which is installed between the double-arch steel wire winding machine body; the planetary roller screw pair is engaged with the clutch and the movable crossbeam (12), which is guided by the slide rail (20) installed on the column (13) of the double-arch steel wire winding machine body. After the clutch is engaged, the movable crossbeam (12) moves downward and contacts the workpiece to complete the striking work. The workpiece is installed on the lower crossbeam (15), which is installed between the double-arch steel wire winding machine body. The double-archway wire winding machine body has two columns (13) on one side, and the upper and lower ends of the two columns (13) are connected to a semi-circular beam respectively. Each semi-circular beam consists of two side crossbeam components (17) and one crossbeam component (16) in the middle. Each column (13) consists of three column components. Each side archway machine body is pre-tensioned with wire winding to form a whole. The upper crossbeam (5) and lower crossbeam (15) installed between the double archway wire winding machine bodies are supported by support studs (18) and fixed by super nuts (19) on both sides with pre-tension, and finally form the whole machine body.

2. The combined lightweight structure according to claim 1, characterized in that: The upper crossbeam (5) includes four symmetrically arranged upper crossbeam sub-components (5-1). Each upper crossbeam sub-component (5-1) has a boss on its upper surface and a flange on its lower surface. Bosses are formed on the four sides of the entire upper crossbeam. Pre-tensioned steel wire is wound in six directions around the entire structure, so that the four upper crossbeam sub-components (5-1) eventually form a whole. The boss on the upper surface of the upper crossbeam is used to support the flywheel assembly. Through holes are machined in the fuselage direction to cooperate with the support studs (18). Semi-circular platforms are machined in the fuselage direction to cooperate with the semi-circular beams of the two side archways. The flange on the lower surface plays a sealing role for the transmission system.

3. The combined lightweight structure according to claim 1, characterized in that: The movable crossbeam (12) includes four symmetrically arranged movable crossbeam sub-components (12-1). Each movable crossbeam sub-component (12-1) forms a flange in the middle of the axial direction. The upper and lower circular surfaces of the flange are wrapped with prestressed steel wire, so that the four movable crossbeam sub-components (12-1) form a whole. Guide blocks are installed at the four corners of the movable crossbeam (12) and connected by bolts. An adjustable slide rail (20) is installed on the machine body. The slide rail (20) cooperates with the guide blocks installed at the four corners of the movable crossbeam to guide the movable crossbeam (12).

4. The combined lightweight structure according to claim 1, characterized in that: The lower crossbeam (15) includes four symmetrically arranged lower crossbeam sub-components (15-1). Bosses are formed on the six surfaces of the lower crossbeam (15) for prestressed steel wire winding, so that the four lower crossbeam sub-components (15-1) form a whole. The lower crossbeam (15) has through holes machined in the direction of the machine body to cooperate with the support studs (18). A semi-circular platform is machined in the direction of the machine body to cooperate with the semi-circular beams of the machine body on both sides. A through hole is machined in the center of the lower crossbeam (15) in the vertical direction for the hydraulic ejection mechanism to remove the billet from the working pad (14).

5. The combined lightweight structure according to claim 1, characterized in that: The steel wire is made of a material with a yield strength of 2000MPa and an ultra-high strength of 65Mn.

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