DILLINGER/SIEMPELKAMP
WELDING
Equally critical is the positioning accuracy of the drive table and moving beam in lowering the 2,500 tonne load at the defined rate of 190 millimetres per second. The 500 meganewton Nanshan press forms only one large structural component per press cycle. It features an additional internal and external line injector for the production of smaller components, such as turbine disks. Pressure distribution plates calculated using the Finite Element Method (FEM) ensure that the specified tolerances of between 0.5 and 1 millimetre are met. “With an 11 metre long moving beam and a tolerance of 1 millimetre per metre, the moving beam may flex only by a maximum of 11 millimetres when 50,000 tonnes of press force are applied”, adds Christoph Schmitz, illustrating the challenges involved. All the pressure distribution plates and the line injector were fabricated from Grade S355JR+N heavy steel plate supplied by Dillinger. The latter was Siempelkamp’s partner of choice for this project, in view of the need to produce heavy plates in a thickness of over 500 millimetre with demanding mechanical properties and deliver them “just in time” within a very narrow time window. “We know, thanks to our many years of cooperation with Dillinger, that we will get the promised quality with total reliability”, affirms Friedhelm Wittenberg, the responsible buyer at Siempelkamp. “The competition can simply not even approach this quality”. A total of twelve such
heavy plates were used, each with as-cast weights of 39 tonnes and more. “The thicker the plates, the better the pressure distribution”, Friedhelm Wittenberg continues. Specific requirements, such as finished dimensions, delivery dates and sequences, mechanical data and a reduced carbon equivalent, were all defined on the basis of intensive interchange with Dillinger. Production of plates of this thickness was a “first”, even for the world’s quality and technology leader in the heavy plate sector. Extremely thick homogenous feed material was cast to order and rolled to finished dimensions under enormous forces in order to assure mechanical properties analogous to those specified in EN 10025 for plate thicknesses of up to 400 millimetres, despite the plate thickness of 510 millimetres for this project. Correspondingly modified rolling-pass schedules made it possible to deform the centre of the plates to the extreme extent required. This also permitted assured adherence to Siempelkamp’s expected flatness tolerances of 13 millimetres across the entire surface area. The highly respectable length of 4.080 mm was not sufficient for some of the components needed for the 500 meganewton press, with the result that Siempelkamp welded three of these plates together using the electroslag welding method for the pressure distribution plates. After final machining, finished dimensions of 4,000 x 7,000 millimetres, with a thickness of 480 millimetres, were achieved. The
(Top & above) Preparation and movement of the heavy components for installation and commissioning of the 500 MN drop-forging press in China.
calculation, design, production, inspection and packing of all 8.000 tonnes of components for the 500 meganewton drop-forging press consumed a total of 40,000 man hours of work. The experts in Krefeld were also responsible for shipment to China, installation and commissioning. In the final analysis, a truly great achievement, made possible only thanks to absolutely perfect interaction between the
units within Siempelkamp and partners such as Dillinger. For more information: Dillinger Dr.-Ing. WolframHölbling Tel: +49 (0)6831/47-47 08 Telef ax: +49 (0)6831/47-99 20 25 e-mail: w olfram.hoelbling@
dillinger.biz
AG der Dillinger Hüttenw erke 66748 Dillingen/Saar Germany POB 15 80
(Left & right) Installation of the 500 MN drop-forging press by Siempelkamp‘s specialists at Nanshan, China.
www.internationalmetaltube.com
IMT December 2018 27
© Siempelkamp
© Siempelkamp
© Siempelkamp
© Siempelkamp
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