12000KN Cold Shear

12000KN Cold Shear

Introduction to Cold Shear

The 12000KN cold shear is a complete set of mechanical, electrical and hydraulic integrated equipment jointly designed and manufactured by foreign parties on the basis of absorbing the technical features of international advanced shearing machines. The cold shear is suitable for shearing small bar, flat steel and other rolled products. It runs smoothly, reliably and has flat section. Each technical index and performance are not lower than that of imported similar products and has a very high cost performance ratio. At the same time, Party B can provide high-quality spare parts in time to ensure stable and reliable operation of Party A's equipment.

Bar Specifications and Steel Grades

Shear steel: 60Si2CrVAT, GCr15, 42CrMo, 60CrMoBA, 51CrV4.

Maximum shear specification: round steel φ 60. Flat steel 53x100 (50CrV4); 40x130 (40Cr).

Main Technical Parameters

Shear force: 15000KN

Shear material: σ Bmax=1865MPa

Maximum shear material specification: φ 60

Maximum number of shear elements ( φ 60): nmax=4 ( σ B=1865MPa)

Max. flat steel size: 53x100

Maximum number of sheared flat steels: 2

Shear frequency: 20 times per minute

Shear opening: 210mm

Blade length: 1400mm

Blade inclination: 2O

Tool Installation: Flat, Forming Knives

Shear temperature: normal temperature (short term 500 oC)

Roller width: 1300mm

Drive motor: 160KW; 1500r/min. AC

Hydraulic clutch brakes (including hydraulic stations) (imported from Germany)

Grease lubrication station, about 23 lubrication points

Cutting machine outline size, length x width x height (mm) 2800x6000x4500 (mm)

The 12000KN cold shearing machine mainly consists of main motor, pulley, flywheel, hydraulic clutch brake, reducer, crankshaft, cutter frame shearing device, frame body, press device, cutter changing device, hydraulic control system, lubrication system and electric control system.

12000KN Cold Shear Structure

Belt Drive

The main motor transfers motion to the flywheel via a triangular belt (the flywheel is connected to the passive pulley) with a transmission ratio of i1=2.3. At this point, the flywheel will save energy.

Hydraulic clutch, brake and reducer

The clutch closes and the flywheel transfers motion to the reducer. When the clutch is opened, the braking function will be achieved, the reducer will stop working and the flywheel will idle. Reducer speed ratio i1=30. Hydraulic clutch brake is an imported component. Hydraulic control system is manufactured in China.

Crankshaft, shearing device

The crankshaft is mounted on the frame body with an eccentricity of 105mm. The crank cutter frame is mounted on the crankshaft and the cutter frame moves up and down in the slide of the frame body. When the clutch is closed, the reducer works and drives the crankshaft to turn. The crank holder moves down rapidly from a high position to achieve shearing (the blade is mounted on the holder via the holder). After shearing, the crankshaft tool holder moves upwards with the crankshaft rotation. When moved to high position, the clutch opens and brakes immediately. At this point, the crankshaft stalls. Wait for the next cycle. Clutch opening, closing and braking are accomplished by a proximity switch controlled hydraulic system.

Frame body and frame are door frame structures of cast-welded structure

The crankshaft is mounted in a copper alloy bushing on the frame. The tool holder is mounted in the frame body slide. The runway is made of copper alloy liners and fitted on the runway. The diagonal sliding plate has the function of adjusting the clearance between the tool holder and the sliding track, and the normal clearance is 0.1mm~0.25mm. Excessive small or large clearance will affect the quality of the section.

Blade clamping and replacement device

The blade is mounted on the upper and lower tool holders, the upper tool holder is mounted on the tool holder, and the lower tool holder is mounted on the tool holder, which is compressed by several butterfly springs. Hydraulic cylinders are installed at the rear of each group of butterfly springs. The blades are replaced hydraulically. The piston of the hydraulic cylinder pushes the butterfly spring to relax the holder and release the holder from the holder. At this point, the hydraulic cylinder piston in the frame body pushes the tool holder out half way. The knife base can be lifted out by the crane. When the new tool holder is lifted into position, the piston of the hydraulic cylinder pulls it into the tool holder position. At this point, the cylinder piston on the rear seat of the butterfly spring exits. The butterfly spring compresses the base of the blade and replaces the old and new blades.

Pressing device

Press device, which is composed of press head, lever and cylinder. Its function is to fix the shear firmly so as to achieve stable shear. Its compression is achieved by an electrically controlled hydraulic system. The position of the press material can be adjusted according to the size of the shear specification and is completed by the hydraulic cylinder.

Hydraulic system

The imported hydraulic clutch brake uses the most advanced hydraulic control system in Germany. The system controls the opening, closing and braking of the hydraulic clutch.

Blade replacement, pushing out and pulling in hydraulic system utilizing existing equipment of Party A. System pressure 12 MPa.

The hydraulic control of the press device is the same as that of the clutch.

lubrication system

Lubrication system (including dry oil pump station) is grease centralized lubrication, which mainly lubricates each sliding bearing and friction pair, about 23 points. Through the grease lubrication station, grease is fed into each lubrication point through the pipe through the distributor.

Electrical control system

The electric control system consists of a control cabinet and an operating platform. The main motor uses frequency-sensitive resistor. Each control point and process control is completed by a Siemens S7-200 programmable controller. Low voltage components are Schneider products.

Please contact stella@hanrm.com for a quotation.
And free send inquiry to us.
Email: stella@hanrm.com   stellarollingmill@gmail.com
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Repair Technology for Bearing Position Wear of Cold Shearing Machine

Repair Technology for Bearing Position Wear of Cold Shearing Machine

Introduction of Cold Shearing Machine

Cold shearing machine is the main equipment for finishing section in bar production line. Its function is to cut the finished rolled piece to a fixed scale. Its structure (see Figure 1) consists of: cutting edge, crankshaft, pulley, electric motor, brake and clutch. The flywheel is mounted on the main shaft, and the motor drives the flywheel to run through the belt. During the shearing action, the clutch connects the main shaft to the flywheel, so that the reducer drives the eccentric wheel to run, and the shearing frame equipped with cutting edges completes the shearing action downwards.

Reasons for Wear of Cold Shear Shaft

In a bar workshop of an iron and steel enterprise, the cold shearing machine suffers from wear problems. The wear location is the mating surface between pulley and spindle. The diameter of the spindle is 180mm and the wear width is 110mm. The damage location is local deep wear, the maximum wear is about 5mm, and the bearing type is SKF2236EC.

Generally, there are many reasons for wear of shaft type. All kinds of defects during manufacture and bad problems in different stages of assembly, maintenance and use during use may cause wear of bearing position. Apart from these problems, the principal reason is that the metal properties used to fabricate shafts are determined by their high hardness, but poor concessionality (which cannot be restored after deformation), poor impact resistance and poor fatigue resistance, which easily lead to adhesive wear, abrasive wear, fatigue wear, fretting wear, etc. Most of the shaft wear problems are not easy to detect. Only when high temperature, large runout, abnormal noise and other conditions occur, most of the shafts have been worn seriously, resulting in machine shutdown.

Repair Process of Cold Shear Shaft

The traditional method to deal with this kind of bearing position wear problem is to transport the shaft to the machine repair plant after disassembly for repair welding and bushing insertion, etc. However, the process of repair welding machine itself is easy to cause local thermal stress on the shaft surface and cause hidden danger of shaft breakage. Moreover, the process of repair welding machine needs a lot of manpower and time to dismantle, transport and install the equipment. The repair time is long and the comprehensive repair cost is high. The cold shearing machine is shut down by accident and must restore the operation of equipment quickly and effectively. Therefore, traditional repair technology is obviously not suitable for this repair of bearing position wear.

Polymer composites can select different repair processes according to the parameters such as rotational speed of equipment, bearing type and service requirements. After observing the field conditions, it is found that a large area of datum surface still exists. Only partial damaged parts can be filled and repaired by materials. Components of the Fossil Blue process can be used to repair the relationship (see Figure 2), which has the characteristics of short repair time, high repair accuracy, low repair cost, no secondary damage to the equipment and easy operation.

Implementation Process of Site Plan

1. Surface treatment: First, bake the worn position to remove the grease which penetrates into the metal micropore;

2. Grinding: Use sandpaper to grind the worn area and clean it with alcohol or acetone.

3. Harmonizing Material: Harmonizing Fossil Blue Proportionally ® 2211F material and stir evenly until there is no color difference.

4. Coating material: Use 2211F material to fill out the wear position and slightly exceed the wear amount.

5. The inner race of the bearing is assembled directly after being dried with mould release agent, and the bearing can be started up after material curing is completed.

Through years of application experience in industrial field, after unexpected sudden shutdown caused by wear of driving parts in enterprises, the technology can make corresponding repair plans according to the operating conditions and design parameters of different equipment and the forming characteristics of polymer composites. It can solve the problem of wear on the transmission part of equipment in the first time, and meet the operation conditions of most equipment to the maximum extent by using the limited basic conditions in the field, thus greatly improving the repair efficiency and accuracy.

Please contact stella@hanrm.com for a quotation.
And free send inquiry to us.
Email: stella@hanrm.com   stellarollingmill@gmail.com
Whatsapp/Wechat:+8615877652925