Calmes 是在(zai)改(gai)進方坯連鑄技術和水壓(ya)穿孔技術兩個方面(mian)技術的基礎(chu)上而發展起PPM技術的,在(zai)PPM發明之前解(jie)決(jue)連鑄坯穿孔問題的幾個途(tu)徑主要是:


  1. 將連鑄方坯軋成圓(yuan)坯后(hou),再用斜軋穿(chuan)孔;


  2. 采用三輥(gun)式穿孔(kong)機對低(di)碳鋼的連(lian)鑄坯(pi)穿孔(kong),至于其(qi)他鋼種,則用經(jing)過(guo)軋(ya)制的連(lian)鑄坯(pi)進(jin)行穿孔(kong);


  3. 在水壓沖孔機上對連鑄坯進行沖孔。


 而PPM可以直接(jie)對連鑄方坯穿孔,這在技術發展史上不(bu)能(neng)不(bu)說是(shi)一(yi)大進步。


 A.H.Calmes 為發展壓力穿孔工藝而做的大量試驗始自20世紀50年代末,于60年代末制成試驗軋機,接著,在Dalmine 不銹鋼管廠進行了工業性試驗。


  1971年(nian)意大利(li) Dalmine 廠建立了(le)一個(ge)(ge)由加熱(re)到(dao)壓力(li)(li)穿孔(kong)(kong)的(de)(de)完整工業性試驗(yan)車間,試驗(yan)證明,壓力(li)(li)穿孔(kong)(kong)工藝可以實現(xian)連鑄方(fang)(fang)(fang)坯(pi)的(de)(de)穿孔(kong)(kong)。所以,1978年(nian)8月(yue)在(zai)意大利(li)Bergamo投產的(de)(de)世界(jie)上第一個(ge)(ge)MPM軋管(guan)廠采用了(le)PPM,這(zhe)臺壓力(li)(li)穿孔(kong)(kong)機(ji)軋輥(gun)輥(gun)徑為(wei)1280mm,電機(ji)功率(lv)為(wei)500kW,推(tui)料機(ji)的(de)(de)最(zui)大推(tui)力(li)(li)為(wei)2300kN.壓力(li)(li)穿孔(kong)(kong)機(ji)前設有(you)兩(liang)個(ge)(ge)導(dao)(dao)向(xiang)(xiang)裝(zhuang)(zhuang)置(zhi)(zhi),一個(ge)(ge)是輥(gun)式導(dao)(dao)向(xiang)(xiang)裝(zhuang)(zhuang)置(zhi)(zhi),另一個(ge)(ge)是板式導(dao)(dao)向(xiang)(xiang)裝(zhuang)(zhuang)置(zhi)(zhi)。后者是日本八幡(fan)廠滾動式導(dao)(dao)板裝(zhuang)(zhuang)置(zhi)(zhi)的(de)(de)一個(ge)(ge)改進,四(si)塊導(dao)(dao)板各由液壓缸(gang)壓向(xiang)(xiang)鋼坯(pi),使方(fang)(fang)(fang)坯(pi)保持在(zai)中心(xin)線上,壓力(li)(li)穿孔(kong)(kong)機(ji)的(de)(de)推(tui)桿是一根圓棒,前端有(you)一個(ge)(ge)方(fang)(fang)(fang)形(xing)推(tui)頭(tou),在(zai)推(tui)桿的(de)(de)中部有(you)一個(ge)(ge)一段(duan)1m左(zuo)右的(de)(de)方(fang)(fang)(fang)形(xing)截面(mian)的(de)(de)導(dao)(dao)向(xiang)(xiang)段(duan),在(zai)其四(si)面(mian)鑲有(you)可以更換的(de)(de)耐磨襯板。在(zai)推(tui)鋼時,這(zhe)一段(duan)方(fang)(fang)(fang)形(xing)導(dao)(dao)向(xiang)(xiang)段(duan)不通過(guo)軋輥(gun),而只(zhi)是在(zai)輥(gun)式導(dao)(dao)向(xiang)(xiang)裝(zhuang)(zhuang)置(zhi)(zhi)中起導(dao)(dao)向(xiang)(xiang)作(zuo)用。


  壓力穿(chuan)(chuan)孔(kong)頂(ding)頭和頂(ding)桿(gan)(gan)擰在(zai)一(yi)起,穿(chuan)(chuan)孔(kong)結束(shu)后(hou),頂(ding)桿(gan)(gan)連同(tong)空(kong)心(xin)坯一(yi)起橫向(xiang)移出(chu)到一(yi)條(tiao)輥道上,在(zai)此(ci)(ci)擋(dang)住穿(chuan)(chuan)孔(kong)坯而將頂(ding)桿(gan)(gan)(及頂(ding)頭)抽出(chu),穿(chuan)(chuan)孔(kong)后(hou)空(kong)心(xin)坯的壁厚不(bu)均平均為(wei)15%,經過一(yi)次延伸(shen)以后(hou),空(kong)心(xin)坯的壁厚不(bu)均可減去70%.因此(ci)(ci)荒管的壁厚不(bu)均約為(wei)±5%,具體數據(ju)是:


 對(dui)于(yu)壁(bi)厚為5.5~6.35mm的(de)鋼管ΔS=±7%;


 對于壁厚(hou)為15~18mm的鋼(gang)管ΔS=3.5%.


  穿(chuan)(chuan)(chuan)(chuan)(chuan)孔(kong)(kong)(kong)(kong)(kong)(kong)后(hou)的(de)(de)(de)(de)空(kong)心(xin)(xin)(xin)(xin)坯(pi)(pi)(pi)要在(zai)(zai)(zai)(zai)延(yan)伸(shen)機(ji)上(shang)延(yan)伸(shen),減小管(guan)壁厚(hou)度,消除壁厚(hou)不(bu)(bu)均。在(zai)(zai)(zai)(zai)1961年(nian)進(jin)(jin)行旨在(zai)(zai)(zai)(zai)消除壁厚(hou)不(bu)(bu)均的(de)(de)(de)(de)試(shi)(shi)驗,采(cai)用了(le)如上(shang)所(suo)述的(de)(de)(de)(de)結構(gou)方(fang)(fang)(fang)(fang)式。后(hou)的(de)(de)(de)(de)1964~1965年(nian)在(zai)(zai)(zai)(zai)一臺(tai)16英(ying)寸周期軋管(guan)機(ji)上(shang)進(jin)(jin)行軋管(guan)試(shi)(shi)驗,其(qi)簡(jian)況如下:管(guan)坯(pi)(pi)(pi)為(wei)(wei)包(bao)括不(bu)(bu)銹鋼(gang)在(zai)(zai)(zai)(zai)內的(de)(de)(de)(de)各種(zhong)(zhong)鋼(gang)種(zhong)(zhong)的(de)(de)(de)(de)6~5/8英(ying)寸方(fang)(fang)(fang)(fang)鋼(gang)錠,穿(chuan)(chuan)(chuan)(chuan)(chuan)孔(kong)(kong)(kong)(kong)(kong)(kong)后(hou)空(kong)心(xin)(xin)(xin)(xin)坯(pi)(pi)(pi)的(de)(de)(de)(de)外(wai)(wai)徑(jing)為(wei)(wei)8 1/4英(ying)寸,壁厚(hou)為(wei)(wei)2英(ying)寸,當(dang)L/I·D為(wei)(wei)12.5時,仍(reng)然(ran)可(ke)獲(huo)得壁厚(hou)均勻的(de)(de)(de)(de)空(kong)心(xin)(xin)(xin)(xin)坯(pi)(pi)(pi)。在(zai)(zai)(zai)(zai)1966年(nian)開始設計(ji)(ji)、制造工藝性試(shi)(shi)驗的(de)(de)(de)(de)壓(ya)力(li)(li)穿(chuan)(chuan)(chuan)(chuan)(chuan)孔(kong)(kong)(kong)(kong)(kong)(kong)機(ji),在(zai)(zai)(zai)(zai)1969年(nian)制成(cheng)試(shi)(shi)驗用的(de)(de)(de)(de)壓(ya)力(li)(li)穿(chuan)(chuan)(chuan)(chuan)(chuan)孔(kong)(kong)(kong)(kong)(kong)(kong)機(ji),所(suo)穿(chuan)(chuan)(chuan)(chuan)(chuan)孔(kong)(kong)(kong)(kong)(kong)(kong)的(de)(de)(de)(de)空(kong)心(xin)(xin)(xin)(xin)坯(pi)(pi)(pi)外(wai)(wai)徑(jing)為(wei)(wei)10~16 1/2英(ying)寸。鑒于采(cai)用連鑄(zhu)方(fang)(fang)(fang)(fang)坯(pi)(pi)(pi)生產(chan)無(wu)縫鋼(gang)管(guan)的(de)(de)(de)(de)重(zhong)要意義,將1968年(nian)試(shi)(shi)驗計(ji)(ji)劃(hua)的(de)(de)(de)(de)重(zhong)點放在(zai)(zai)(zai)(zai)連鑄(zhu)坯(pi)(pi)(pi)的(de)(de)(de)(de)穿(chuan)(chuan)(chuan)(chuan)(chuan)孔(kong)(kong)(kong)(kong)(kong)(kong)上(shang),接著(zhu)采(cai)用各種(zhong)(zhong)鋼(gang)種(zhong)(zhong),特(te)別(bie)是在(zai)(zai)(zai)(zai)斜軋穿(chuan)(chuan)(chuan)(chuan)(chuan)孔(kong)(kong)(kong)(kong)(kong)(kong)機(ji)上(shang)難以穿(chuan)(chuan)(chuan)(chuan)(chuan)孔(kong)(kong)(kong)(kong)(kong)(kong)的(de)(de)(de)(de)鋼(gang)種(zhong)(zhong),進(jin)(jin)行了(le)大(da)量(liang)的(de)(de)(de)(de)壓(ya)力(li)(li)穿(chuan)(chuan)(chuan)(chuan)(chuan)孔(kong)(kong)(kong)(kong)(kong)(kong)試(shi)(shi)驗,其(qi)結果如下:9 1/2英(ying)寸連鑄(zhu)方(fang)(fang)(fang)(fang)坯(pi)(pi)(pi),經(jing)過加熱、定心(xin)(xin)(xin)(xin)、定型和(he)清除氧(yang)化鐵(tie)皮后(hou),在(zai)(zai)(zai)(zai)壓(ya)力(li)(li)穿(chuan)(chuan)(chuan)(chuan)(chuan)孔(kong)(kong)(kong)(kong)(kong)(kong)機(ji)穿(chuan)(chuan)(chuan)(chuan)(chuan)成(cheng)空(kong)心(xin)(xin)(xin)(xin)坯(pi)(pi)(pi),其(qi)外(wai)(wai)徑(jing)為(wei)(wei)11 3/4英(ying)寸,內徑(jing)為(wei)(wei)6英(ying)寸,方(fang)(fang)(fang)(fang)坯(pi)(pi)(pi)穿(chuan)(chuan)(chuan)(chuan)(chuan)孔(kong)(kong)(kong)(kong)(kong)(kong)時的(de)(de)(de)(de)延(yan)伸(shen)系(xi)數(shu)(shu)為(wei)(wei)1.08~1.18,通(tong)過軋輥(gun)孔(kong)(kong)(kong)(kong)(kong)(kong)型以及出口導(dao)套的(de)(de)(de)(de)變換,可(ke)以改(gai)變空(kong)心(xin)(xin)(xin)(xin)坯(pi)(pi)(pi)的(de)(de)(de)(de)外(wai)(wai)徑(jing)和(he)延(yan)伸(shen)系(xi)數(shu)(shu)。當(dang)延(yan)伸(shen)系(xi)數(shu)(shu)為(wei)(wei)1.10時所(suo)得的(de)(de)(de)(de)結果為(wei)(wei)最(zui)(zui)好,截面也(ye)較圓。但應(ying)指出,壓(ya)力(li)(li)穿(chuan)(chuan)(chuan)(chuan)(chuan)孔(kong)(kong)(kong)(kong)(kong)(kong)法的(de)(de)(de)(de)目的(de)(de)(de)(de)并不(bu)(bu)在(zai)(zai)(zai)(zai)于獲(huo)得完全圓的(de)(de)(de)(de)空(kong)心(xin)(xin)(xin)(xin)坯(pi)(pi)(pi)和(he)較巨大(da)的(de)(de)(de)(de)延(yan)長率,而是在(zai)(zai)(zai)(zai)不(bu)(bu)使金屬結構(gou)受到不(bu)(bu)利的(de)(de)(de)(de)應(ying)力(li)(li)狀態下,將方(fang)(fang)(fang)(fang)形鑄(zhu)坯(pi)(pi)(pi)穿(chuan)(chuan)(chuan)(chuan)(chuan)孔(kong)(kong)(kong)(kong)(kong)(kong)成(cheng)為(wei)(wei)內表(biao)面質量(liang)良好的(de)(de)(de)(de)圓形空(kong)心(xin)(xin)(xin)(xin)坯(pi)(pi)(pi),最(zui)(zui)大(da)的(de)(de)(de)(de)穿(chuan)(chuan)(chuan)(chuan)(chuan)孔(kong)(kong)(kong)(kong)(kong)(kong)比L/I·D可(ke)達24,而在(zai)(zai)(zai)(zai)水壓(ya)沖孔(kong)(kong)(kong)(kong)(kong)(kong)機(ji)上(shang),穿(chuan)(chuan)(chuan)(chuan)(chuan)孔(kong)(kong)(kong)(kong)(kong)(kong)比僅為(wei)(wei)6,若其(qi)后(hou)設置延(yan)伸(shen)機(ji),也(ye)只能達到9,在(zai)(zai)(zai)(zai)壓(ya)力(li)(li)穿(chuan)(chuan)(chuan)(chuan)(chuan)孔(kong)(kong)(kong)(kong)(kong)(kong)機(ji)上(shang),雖然(ran)L/I·D值很高,但其(qi)壁厚(hou)的(de)(de)(de)(de)偏差仍(reng)在(zai)(zai)(zai)(zai)允許范(fan)圍內。


除(chu)了加熱均(jun)勻與否以外(wai),影響壁厚不均(jun)程(cheng)度的主要因素(su)是:


  1. 設計方面的(de)因素(su) 入(ru)口導套、出口導套、軋輥孔型、頂桿的(de)中心要在一條(tiao)直(zhi)線上;


  2. 工具方面(mian)的(de)因素 要將(jiang)穿(chuan)孔工具的(de)公差(cha)值(zhi)減至最小(xiao);


  3. 定心問題 在方(fang)坯(pi)的前端要有(you)一個準確的中(zhong)心孔;


  4. 穿孔頂頭和頂桿(gan)(gan)的(de)強度問題 當方坯加熱溫度為(wei)2300~2360 ℉時,頂桿(gan)(gan)的(de)單位載荷不應超過65kg/m㎡.