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江苏森威的精密锻造江苏森威精锻有限公司创建于1958年，曾经是中国最大的自行车零件工厂，主要成形工艺是热锻。Jiangsusunwayprecisionforgingcompanylimitedwasfoundedintheyearofninteenfifty-eight,itwasthebiggestbicyclepartssupplierinchina,andthemainformingtechniquewasthehotforging.1985年，森威公司从日本引入冷锻压力机和冷锻技术，开始自行车飞轮和变速器的冷锻生产。Intheyearofninteeneighty-five,Sunwayimportedthepressandthecold-forgingtechniquefromJapan,andthenbegantomaketheflywheelandtransmissionbythecold-forming.90年代末，中国汽车工业起步。江苏森威开始将精密成形技术用于汽车零部件的开发和生产。Intheendofnineties,theautomobileindustrywasstarting.Atthattime,sunwayhadbegantofocusontheprecisionsizingfortheautomobilepartsdevelopmentandmanufacture.这是当时开发和投入生产的一些精密锻件：Thefollowswerethemainpartswhichwedevelopedandmanufacturedatthattime:1）汽车等速万向节滑套；CV-jointtripothousing2）汽车等速万向节星形套和三销轴；CV-jointinner-raceandspider3）汽车变速箱输入/输出轴冷锻毛坯；Blankoftheinputandoutputshaftfortheautomobile-transmission4）花键轴；Spline-shaft5）各种齿轮，等等。Variousgearsect.目前，江苏森威精锻掌握并用于生产的精密成形技术有：Atthemoment,sunwayhadmasteredtheprecisionformingtechniqueandalsoappliedtomanufactureasfollows:1．等速万向节外套的温-冷联合成形技术：Warmandcoldforgingforthecv-jointtrpothousing1）上世纪90年代，国内等速万向节生产刚刚起步，CV精密锻件需求较少，我们用单工位液压机组成温锻生产线。Intheninteen-nineties,theproduceofthecv-jointjuststartedinChina,andthedemandsweresmall,so,wejustonlyusedone-stationhydraulicpresstomakeupthewarm-forgingproductionline.2）90年代末，引进Schuler公司的SMG-1000吨三工位手动温锻生产线，生产效率和锻件质量都有所提高；Intheendofnineties,theSchulerSMG10000kNthree-stationpresswasintroduced,theefficientandtheforging’squalitywasimprovedalot.3）近年来，国内汽车行业对等速万向节的需求猛增，森威精锻引进日本Kurimoto公司2000吨5工位温锻自动线。该生产线将在今年的12月投产，将缓解森威精锻的等速万向节精锻毛坯供不应求的局面。3）Recentyears,thedemandsofthecv-jointtripothousingtakesajump,sunwayhadimportedthefive-stationstwo-thousandtonwarm-forgingautomatic-productionline.ThislinewillgointoproductioninDecemberofthisyear,anditwillrelievethecv-jointtrpothousingsituationofdemandoversupplyatthemoment.2．长轴的可分凹模挤压技术：two-partmouldextrusiontechniqueofthelongshaft以汽车变速箱输入轴为代表的长台阶轴的成形，如采用正挤压成形时，往往退料的难度大于挤出。因此，传统的成形方法是多次减径挤压工艺。Therepresentativepartsaretheautomobiletransmissioninput-outputshafts.ifadoptsthewayofforwardextrusion,theejectionwashardthantheextrusion.So,thetraditionalmethodwasironingformanytimes.但多次减径在设计不当时，长轴端部最细杆的心部有产生中心爆裂的风险。Butiftheironingdesignisnotright,theendoftheminimumdiametercentrehadtheriskofcentreburst.森威精锻采用的方法是：将长轴的最小直径尽量在一次正挤压工序中完成。Sunway’smethodis:weextrudetheminimumdiameterinforwardextrusiononetimeaspossibleaswecan.为保证顺利退料，我们采用了可分凹模的结构。在正挤压毛坯顶出前先使可分凹模的上半模脱离工件，从而使毛坯顶出力减少一半左右，保证了退料的顺利进行。Indertoguaranteethepartsejectedsmoothly,weusethetwo-partmouldstructure.beforethepartejectfromthemould,theupper-mouldhaddischargedfromthepart,thatmeansitwillreducethehalfstrengthoftheejection,andthenguaranteethepartsejectsmoothly.由于正挤压过程是在三向压应力状态下完成，减少了发生中心爆裂的风险。Sincetheforwardextrusionwascompletedunderthethreecompressivestress,itreducedthecentreburstgreatly.3．采用高压氮气作为闭塞动力源的气动闭塞模架Adoptthehighpressurenitrogentobethepneumaticdie-setsofthepowersupply1）森威精锻采用高压氮气作为闭塞动力源，结构简单，使用成本很低。生产中高压气缸即使发生轻微泄漏，也不会污染环境。Sunwayusesthehighpressurenitrogentobethepowersupply,thestructureissimpleandthecostislow.eventhehighpressurelightleakinproduction,itwouldnotpollutetheenviroment.因气体具有可压缩性，能吸收冲击，因此，气动闭塞系统能够在频繁冲击状态下工作。在肘杆式冷锻压力机上进行闭塞锻造时，滑块在锻造过程中的加速度很大，液压闭塞系统往往会在频繁冲击下出故障，但气动闭塞系统仍能正常运行。气动闭塞系统动作可靠，经济性好，被森威精锻广泛应用与当前的闭塞锻造生产中。Sincethegashasthecompressibility,itcanabsorbtheimpact.so,thepneumaticblocksystemmayworkunderthefrequencyimpact.Whendotheclose-forgingunderthetogglepress,theslide’sacceleratedspeedwasrapid.Underthisfrequencyimpacts,thehydraulicblocksystemalwaysfailureeasily.Butthepneumaticblocksystemcanrunsmoothly.thepneumaticblocksystemisreliable,economical,itwasusedwidelyintheclose-forginginsunway.2）在双向对称闭塞锻造场合，我们在气路中插入2个单向阀，使上、下2个气缸等效为2个刚性系数K相同的大吨位弹簧。根据弹簧的压力随弹簧的压缩变形量增加而线性增大的原理（δP=K×δL），省去了上、下冲头的同步机构，使双向闭塞模架变得与单向闭塞模架一样简单可靠。Thedoubleclose-forgingsituation,weinsettedtwoone-wayvavlestomakeupperanddowntwoair-cylindersequaltotwosamehightonspring.refertothespring’s,omittedupperanddownpunch,thenmadethetwoblockdie-setbecomesimple,reliableastheonewayclosedieset.3）森威精锻在闭塞锻造方面的最新改进方案是以氮气弹簧标准件来替代特别设计的高压气缸，从而降低模架的制造难度、减少气体泄漏，提高模架使用寿命。Sunway‘slatestimproveprogrameinclose-forgingistousethespringstardardunitsinsteadofthespecialdesign’shighpressureaircylinder,thenitreducethedie-set’smanufacuturedifficultiesgreatly,thegasleakage,alsoimprovethedie-set’susagelife.当前，江苏森威精锻的精密锻件年产量接近2.5万吨，主要生产技术多为自主开发。Atthemoment,sunway’sprecisionforgingpartsannualproductioncapacitynearlyupto25,000ton,andthemostofthemweredevelopedindependently近年来，为了尽快满足客户在精锻产品质量和产量方面不断增长的需求，森威精锻通过一系列的技术引进，引入了国外先进技术和设备：Recently,inordertosatisfythecustomer’srequirementsofhighquantityandquantity,sunwayhadbringtheoverseasupertechniqueandalsothefacility.1）从日本Nichidai公司引入齿轮的分流成形技术1)ImportthegeardistributionformingtechniquefromNichidaiJapan2）从瑞士哈特贝尔公司引进MP30S高速热镦锻机；ImporttheMP30ShighspeedhotforgingpressfromtheHatbur.3）从日本Kurimoto和Nichidai公司引进的多工位温锻生产线和温锻模具技术；Importthemulti-stationswarm-forgingproductinlineandwarm-foringtoolingtechniquesformtheKurimotoandNichidaiJapan.4）从瑞士米克朗公司引入的高速铣