TECHNOLOGICAL POTENTIALITIES OF THE PLANT Е

METALLURGICAL PRODUCTION

1. Press-forging shop;
2. Steel-casting department;
3. Metallurgical production;
4. Blanking-welding fabrication;
5. Machine-assembling production;
6. Other potentialities.;

MACHINE - ASSEMBLING PRODUCTION

1. Blanking fabrication:
- Bar cutting with Geller's saw;
- Bar cutting with multipurpose shears;
- Plate (sheet) cutting;
- Plate straightening after cutting;;
- Plate bending;
- Plate expanding;
- Production of welded metal works.

2. Machining
- Turning;
- Boring;
- Processing centers (boring);
- Deep boring (cylinder treatment);
- Cylindrical grinding;
- Internal grinding;
- Thread grinding;
- Worm grinding;
- Flat-longitudinal grinding (item dimensions);
- Flat grinding (item dimensions);
- Longitudinal-milling (item dimensions);
- Longitudinal-milling with CNC (item dimensions);
- Longitudinal shaping (item dimensions);
- Gear-milling with formed cutters (item dimensions);
- Gear-generating (item dimensions);
- Gear-generation for racks (item dimensions);
- Gear-milling special machining (item dimensions);
- Worm-milling (item dimensions);
- Lifting equipment.

Assembling shops of the enterprise

METALLURGICAL PRODUCTION.

1. Press-forging shop.

A. Forgings of ingots with 2000-ton press
1. Smooth shafts;
2. Shafts with shoulders;
3. Crankshafts and eccentric shafts;
4. Forgings of rectangular section
5. Plates
6. Rods
7. Pinions, wheels, coupling and other similar items without' broaching;
8. The same with broaching;
9. Formed cubes and those of simple carbon steel;
10. Expanded rings.
Note: Maximum permissible ingot to be used on the press - 10 t. (it is stipulated by the load-carrying capacity of forging manipulator).
Maximum mass of forging - 6.0 t.

B. Forgings of rolled stock and broaching with hammers (of the most various forms and kinds).
Min. mass - 0.2 kg; max for shafts and plates - 1200 kg. (limited load - carrying capacity of manipulator).
Max. mass for pinions and cubes - 320 kg. With the 3.15 - ton hammer we can make forgings of ingots having the mass of 1 ton and the section not over 300 mm.

2. Steel department.

Steel cast shapes weighing 50 - 5000 kg, with overall dimensions up to 4300 x 2300 x 2100 mm of steel 25Ћ, 35Ћ and 45Ћ per GOST 977-88.
We can cast frames, uprights, rams, connecting rods, wheels, flywheels, anvil blocks, plates, charging boxes and other parts. The drop hammers and armour plates are casted of rimming steel 3 ѕ.

FORDING INGOTS weighing 4250-8200 kg of carbon and low-alloyed steels - steel 20, 35, 45, 40, 40XHMA, 5XHM and others.

IRON CAST shapes weighing 20 - 5000 kg, overall dimensions up to 3000 x 1600 x 1100 mm.

IRON CHILL casting weighing up to 350 kg of simple geometrical forms -plates, bushes, billets, simicouplings and other.
Iron casting is made of grey cast iron - C40, C415 and C418 per GOST 1412-85.

ќWear resistant alloy cast iron 4H2X GOST 7769-82 is put into production.

The quantity of forgings, steel and iron casting is not limited in the order.

3. Metallurgical production

Steel cast shapes: of steel grades 25, 35, 45 and others according to agreement, weighing from 0.5 to 5 t, overall dimensions from 1000 up to 3000 mm. Ingot production weighing up to 8 t.
Iron cast: castings of base members and location parts, parts of bodies of revolution type of grey cast iron C4-20 weighing from 50 up to 5000 kg and with overall dimensions up to 2000x2000x2000 mm. Cast iron billets with diameter from 70 to 300 mm, length up to 1000 mm.
Floor plates, canalization and phone man-holes.

Forgings of rolled stock: of any grade of steel weighing from 10 up to 300 kg.
Forgings of ingots: grades of steel 35, 45, 40X, 40XH, 5XHMA and others according to arrangement, weighing from 1.0 to 6.0 t.

Shaft blanks, 550 mm diameter, 5500 mm length.
Pattern components of customer's materials.

4. Blanking - welding production.

The blanking welding production is equipped with modern machines to cut the rounds with section up to 500 mm, plates with thickness of 150 mm using gas-cutting devices with control program as well as semi-automatic welding for making the welded constructions weighing up to 50 t.

5. Mechanical - erecting production.

The mechanical - erecting production is equipped with unique processing centers, coordinate - boring and coordinate - grinding machines, borers, planers, grinders and other machines, equipped with numerical programmed control which permit to machine the casting, welded constructions and base members weighing up to 30 t.
It is carried out the assembly and adjustment of equipment with programmed control system, automatic and semi-automatic lines, automatic and semi-automatic machines for various productions.
Using the customer's drawings we can manufacture:
- hydro and pneumatic cylinders with diameter from 90 to 400 mm, piston travel up to 6000 mm;
- bodies for carrying the goods (inside factory and inter-shop transportation) up to 30 t;
- traveling cranes, floor operated, load-carrying capacity up to 5 t;
- wall-mounted derrick cranes, load-carrying capacity up to 2 t;
- conveyers, screens, separators of ferrous metal.

6.6. Other potentialities:

MECHANICAL - ERECTING PRODUCTION.

1. Blanking production.

Bar cutting with Geller's saws Е Ø8 Е 500 mm.
Bar cutting with multipurpose shears:

Plate cutting:

- With shears: plate thickness - 1... 25 mm; plate width - max 300 mm.

- CNC gas-cutting semi-automatic machines (programmed systen of nesting of blanks):
- plate thickness - 5 ... 200 mm;
- plate width - max. 3500 mm;
- plate length - max. 8000 mm.

Plate straightening after cutting:
- plate thicknedd - 4 - 24 mm;
- maximum plate width (at plate thickness - 4 mm) - 1000 mm.

Plate bending:
- plate thickness - 1 - 20 mm;
- maximum width - 3150 mm.

Plate rolling:
- plate thickness - 1 ... 10 mm;
- max. plate thickness - 2000 mm;
- min. radius - 95 mm;
- max. radius - depending on width.

Production of welded metal constructions:

- Maximum dimensions of welded constructions:

   
On bench plate
When using special equipment
Length
4500 mm
7500 mm
10000 mm
Width
3900 mm
3900 mm
3900 mm
Height
2800 mm
2800 mm
2800 mm

- thickness of butt welding plates

 
Single-side welds
Double-side welds
Manual arc welding
1,5 Е 100 mm
1,5 Е 175 mm
—ќ2 semi-automatic welding
4,0 Е 150 mm
4,0 Е 150 mm

- dimensions of welded constructions subjected to shot blasting:
- length -
- width -
- height -
- max. weight of welded constructions - 25.0 t.

2. Machining.

Turning

- CNC machining:

diameter, max.
400 mm.
length, max.
2000 mm

- Vertical machining:

max. diameter
3150 mm
max. height
1600 mm
max. weight
16,0 t.

- Turning:
Max. diameter:
- above frame - 1250 mm;
- above carriage - 900 mm.
Max. length - 12300 mm.


Ј Boring:

Max. upright displacement
9000 mm
4000 mm
Max. spindle head displacement
2000 mm
3150 mm
Max. axial displacement of spindle
1240 mm
1600 mm
Max. diameter of holes to be machined
1240 mm
1000 mm
Plate dimension
8500х4660 mm

Ј ЈProcessing centres (boring))

- Working surface of table 630x800 mm;
- Height of article - 600 mm;
- Weight of article - 800 kg.


Ј Deep boring (cylinder machining)

- Dimensions of articles to be machined:

Diameter
Length
80 Е 160
1600
100 Е 500
4000
125 Е 500
2800

Ј Cylindrical grinding:

Maximum dimensions of article:

Diameter
Length
800
600

Ј Cylindrical grinding

 
Diameter
Length
Max. dimensions of article
800
6000

Max. dimensions of grinding:

of steadyrest

without steadyrest

 

400

710

 

5600

5600

Ј Internal grinding:

Outside diameter
Grinding diameter
Length of grinding
800
25 Е 400
420

Ј Thread grinding: 200 Е 475

Ј Worm grinding: 168 Е 2000

Ј Surface-longitudinal grinding (article dimensions)

Length
Width
Height
4000
1000
800

Ј Surface grinding (article dimensions)

Length
Width
Height
2000
630
630

Ј Longway milling (article dimensions)

Length
Width
Height
Weight, t
6000
2500
2500
-
6000
1810
1800
14,0

Ј CNC longway milling (article dimensions)

Length
Width
Height
Weight, t
6000
2500
2500
-
6000
1810
1800
70,0

Ј Longitudinal planing (article dimensions)

Length
Width
Height
Weight, t
8000
2500
2450
45,0
8000
1600
1400
10,0

MODULE

Ј Gear milling

Diameter
Tooth width
Steel
Cast iron
1500
500
15
20

Ј Gear shaping

Diameter
Tooth width
Steel
Cast iron
800
170
12
12

Ј Gear shaping (for racks)

Diameter
Tooth width
Steel
Cast iron
1110
170
12
12

Ј Special gear milling

Diameter
Length
Modulus
Weight, t
50 - 500
6000
20 - 25
6,0

Ј Worm milling

Diameter
Length
Modulus
Weight, t
320
6000
10 - 18
-

Ј Lifting facilities of mechanical shops (t):

 
Basic
Shafts bay
Plane parts
Shop є 5
50
9
5
Shop є20
30
5
5
Shop є21
-
5
-

Assembly shop of plant

 
Shop є7
Shop є18
Arbitrary area, m2
3000
3368
Max. load - carrying capacity of cranes (t)
50
50

Max. height of crane hook lifting

- old shop

- new shop

 

10000

11000

 

-

11000

Max. height of gate

- old shop

- new shop

 

4340

4440

 

-

4200

Height from platform to gate top

- old shop - new shop

- new shop - painting bay

 

3340

2800

 

-

3200

 


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