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Machinery Industry Standard of the People's Republic of China
JB/T2403.3—96
Roll Forging Machine
Published on April 11, 1996
Technical Conditions
Implemented on October 1, 1996
Ministry of Machinery Industry of the People's Republic of China
Machinery Industry Standard of the People's Republic of China
Technical Conditions for Roll Forging Machine
1 Subject Content and Scope of Application
JB/T2403.3-96
Replaces JB3845—85
This standard specifies the technical requirements, test methods, inspection rules, packaging, marking and transportation, and random technical documents for roll forging machines. This standard applies to various types of roll forging machines for hot roll forging. 2 Reference standards
GB1184
GB3766
GB5226
GB/T13306
JB2131
JB/T2403.1
JB/T2403.2
JB3240
JB3623
ZBJ50011
ZBJ50013
ZBJ50014
ZBJ62001
3 General requirements
Packaging, storage and transportation Pictorial marking
Shape and position tolerance Provisions for tolerances not specified General technical conditions for hydraulic systems
General technical conditions for machine tool electrical equipment
General technical conditions for hydraulic components
Parameters of roll forging machine
Accuracy of roll forging machine
Visual symbols for forging machine operation instructions
Method for measuring noise of forging machine
Technical conditions for machine tool painting
Technical conditions for machine tool rust prevention
Technical conditions for machine tool packaging
Hydraulic system of forging machine
3.1 Drawings and technical documents
Cleanliness
The drawings and technical documents of roll forging machine shall comply with the requirements of relevant national standards and this standard, and shall be put into production (including non-standard products) after approval in accordance with the prescribed procedures.
3.2 Types and parameters
The types and basic parameters of roll forging machine shall comply with the relevant standards. The basic parameters of double-bearing roll forging machine shall generally be selected in accordance with the provisions of JB/T2403.1.
3.3 The design and manufacture of forging rollers shall comply with the following provisions. 3.3.1 The coaxiality of the forging roller support journal, the cylindricity of the working journal or the straightness of the axis, the radial runout of the working journal, and the end face runout of the die positioning surface to the support journal shall not be less than the 7th grade accuracy specified in GB1184. 3.3.2 The surface roughness R value of the journal is 0.63~1.25μm, and the hardness of the working journal is not less than 230HB. 3.4 Matching parts and matching
3.4.1 The forging machine shall be equipped with the accessories, tools and spare wearing parts necessary to ensure the basic performance of the machine and normal installation and adjustment when it leaves the factory. Special accessories shall be agreed upon by the user factory and the manufacturer, and shall be supplied randomly or ordered separately. 3.4.2 The manufacturer shall ensure that the purchased parts meet the current standards or obtain the certificate of conformity, and shall be installed on the forging machine and tested at the same time. Approved by the Ministry of Machinery Industry on April 11, 1996
19%-10-01 Implementation
3.5 Quality of castings, forgings and weldments
JB/T2403.3-96
3.5.1 All iron castings, steel castings, non-ferrous metal castings, forgings and weldments on the roll forging machine shall meet the current standards. If there is no standard, it shall meet the technical requirements of the drawings and process documents. Important outsourced castings and forgings shall obtain a certificate of conformity. For defects that do not affect the use and appearance, repairs are allowed according to the specified technical documents under the condition of ensuring quality. 3.5.2 There shall be no cracks in the castings, and there shall be no sand holes, pores or shrinkage on the joint surface and exposed processing surface of the castings. Bearings, nuts, gears, and worm wheels should not have cold shuts, slag inclusions, and segregation. Defects in cast iron parts may be repaired according to the technical conditions for repairing defects in machine tool gray cast iron parts. 3.5.3 The surface of the casting should be flat, and the flatness error of the non-machined surface should not exceed 3mm over any 600mm length. 3.5.4 Important castings and welded parts that may produce stress deformation or are subject to large forces after processing should be aged or eliminated by other methods.
3.6 Processing and assembly quality
3.6.1 The processing of parts should comply with the requirements of design, process and relevant standards. The processed surface should not have burrs, marks, and other mechanical damage. Except for special provisions, sharp edges should be blunted. 3.6.2 The contact condition of bearings, shafts, or sleeves processed by fine boring, milling, or other mechanical methods should be checked by coloring, and the contact should be uniform. The cumulative index of the contact area should not be less than 70% of the axial length of the sleeve and bearing. 3.6.3 The outer diameter of the separable bearing and the bearing seat should be in close contact, and the matching properties should meet the design and process requirements. 3.6.4 The roll forging machine should be assembled according to the assembly process regulations during installation. It is not allowed to install gaskets, sleeves, etc. that are not specified in the drawings. 3.6.5 The joint surfaces between the frame and the base, the box and the base, and the frame and the box are important fixed joint surfaces and should be tightly fitted. Use a 0.04mm feeler gauge to check. Only partial insertion of the feeler gauge is allowed. The insertion depth shall not exceed 1/4 of the contact surface width. The cumulative length of the feeler gauge between the contact surfaces shall not exceed 1/10 of the circumference.
3.6.6 The axial misalignment of the meshing gears shall not be greater than the provisions of Table 1. Table 1
Small gear rim width B
>50~150
Center misalignment is not greater than
3.6.7 Static balance test and calibration shall be carried out before the flywheel of the roll forging machine is installed. In the idle running test after the roll forging machine is assembled, no obvious vibration is allowed.
3.6.8 The circular runout of the flywheel should be checked after the flywheel is assembled (or assembled). The circular runout error shall not be greater than the specified in Table 2 Table 2
Flywheel diameter D
>1000~2000
Circular runout tolerance
Note: When measuring, the indicator is placed on the measured surface of the flywheel in the radial direction and the end face (10mm away from the outer corridor of the flywheel), and the flywheel is rotated by hand. When the flywheel rotates one circle, the maximum reading difference of the indicator is the circular runout error. 3.6.9 The operation of the handle, handwheel, pedal device, etc. must be flexible and reliable. The operating force of the frequently used handle and handwheel should not be greater than 40N; the operating force of the pedal device should not be greater than 60N. 3.7 Quality of hydraulic, lubricating, pneumatic and electrical devices 3.7.1 Hydraulic system
JB/T2403.3—96
a. The technical requirements of the hydraulic system of the roll forging machine shall comply with the provisions of GB3766, and all hydraulic components in the hydraulic system shall comply with the provisions of JB2131.
b. Both ends of the hydraulic pipeline shall be marked for easy inspection and maintenance. 3.7.2 Lubrication
The lubrication points of the lubrication device shall be reasonably and firmly set, and the operation shall be reliable. The lubricating oil shall not seep or leak. 3.7.3 Pneumatic system
All pipelines, joints, flanges, cylinders, guide sleeves, pistons, etc. of the pneumatic system shall be well sealed, reliably connected, and shall comply with the relevant standards.
The working parts shall not creep, stagnate or vibrate within the specified range, and there shall be no significant impact when reversing and unloading. 3.7.4 Pressure vessels
The design, manufacture and inspection of pressure vessels must comply with the provisions of relevant standards and regulations. 3.7.5 Electrical system
The electrical equipment of the roll forging machine shall comply with the provisions of GB5226. 3.8 Appearance quality
3.8.1 Appearance of the machine
The appearance of the roll forging machine shall be flat and smooth, and shall not have protrusions, depressions, roughness and other damage not specified in the drawings. There shall be no obvious misalignment on the joint surfaces of parts and components, and the joints between sheet materials and cast doors and covers shall be flat, without obvious gaps and misalignment. 3.8.2 Welds
Exposed welds shall be trimmed straight and uniform, and shall comply with the provisions of relevant standards. 3.8.3 Bluing and electroplating
The surface of blueing and electroplating parts shall be smooth and free of rust. 3.8.4 Exposed fasteners
Countersunk screws should not protrude from the outer surface of parts: fixing pins should generally protrude slightly from the outer surface of parts; the tail end of the bolt should protrude from the nut, but the protruding part should not be too long or uneven. 3.8.5 Pipelines and lines
The pipelines and lines of various systems should be installed neatly and beautifully, and should not rub or collide with other parts. 3.8.6 Signs and logos
a. There should be signs, operation, instructions, lubrication, safety signs or logos on the roll forging machine. The visual symbols of operation instructions should comply with the provisions of JB3240, and the type and size of the signs should comply with the provisions of GB/T13306. b. The fonts of various signs on the roll forging machine should be clear, the fixing position should be obvious, and the fixing should be flat, firm and not skewed. 3.8.7 Painting
The painting technical requirements of the roll forging machine shall comply with the provisions of ZBJ50011. 4 Test methods
4.1 The inspection and test of the roll forging machine include the following: a. Inspection of basic parameters and dimensions;
b. Idle running test:
c. Load test;
d. Overload test;
e. Accuracy inspection.
4.2 Inspection of basic parameters and dimensions
The basic parameter inspection shall be carried out under no-load conditions, and the actual measured error shall not be greater than that specified in Table 3. 3
Inspection items
Forging roll diameter
Forging roll speed
Forging roll center distance adjustment
Note: ①Inspection shall be carried out under normal power supply conditions. JB/T2403.3—96
②If the error conversion result is less than 1mm, it shall still be calculated as 1mm. 4.3 Idle running test
5% of the speed
4.3.1 The idle running test of the roll forging machine includes: continuous running test, single running test, and inching adjustment test. 4.3.2 The continuous idle running test time of the roll forging machine shall generally be no less than 4h, of which the continuous running test shall be no less than 2h and the single running test shall be no less than 1.5h.
4.3.3 During the single running test, the number of times the clutch and brake are engaged shall not be less than the requirements of Table 4. 4.3.4 During the idle running test, the temperature rise of the sliding bearing shall not exceed 35℃, and the maximum temperature shall not exceed 70℃; the temperature rise of the rolling bearing shall not exceed 30℃, and the maximum temperature shall not exceed 60℃. Table 4
Forging roll revolutions
The number of clutch and brake engagements per minute to the forging roll revolution per minute%25
4.3.5 The friction clutch, brake and electromagnetic control valve shall move smoothly and in coordination during the single running test (including inching adjustment). During the test, the temperature rise of the friction clutch shall not exceed 70℃, and the maximum temperature shall not exceed 100℃. 4.3.6 When a single operation stops, the forging shall stay in the specified position reliably, with a tolerance of 5°. 4.3.7 When the single operation is in working order, continuous operation shall not occur. 4.3.8 The working conditions of the electrical, hydraulic, pneumatic lubrication system and its accessories shall be normal and reliable, and there shall be no blockage and leakage in the hydraulic gas pipeline in the working system.
4.3.9 The gear transmission machinery, electrical and electric components of the roll forging machine shall not have abnormal impact and screaming when working. The noise limit shall comply with the provisions of Chapter 5 of this standard.
4.3.10 The time of the inch adjustment test shall be no less than 5min, and the interval of each inch adjustment shall be 3s. The action shall be sensitive and reliable. 4.3.11 The center distance adjustment, angle adjustment and axial adjustment shall be carried out according to the adjustment amount specified in the design, and the operation shall be normal. 4.4 Load test
The roll forging machine shall be subjected to load test according to the method specified in Appendix A (reference part) for not less than 3 times. During the test, the actions of all mechanisms shall be coordinated and reliable.
4.5 Overload test
4.5.1 The roll forging machine shall be subjected to overload test at 120% of its nominal force for not less than 3 times. The test method shall be in accordance with the provisions of Appendix A. During the test, all mechanisms shall work normally and parts shall not be damaged. 4.5.2 The correctness and reliability of the overload protection device shall be assessed according to the design requirements. For mechanical overload protection devices, the shear performance test shall be carried out on the shear block separately according to the design requirements. 4.6 Accuracy test
4.6.1 Each roll forging machine shall be subjected to accuracy test after the idling test and load test, and shall comply with the provisions of JBT2403.2. 4.6.2 The actual measured data of the accuracy test after the load test shall be recorded in the certificate of conformity. 4
JB/T2403.3—96
Measurement method and limit of A-weighted sound power level Lw and A-weighted sound pressure level L of roll forging machine noise 5.1
The measurement method of roll forging machine noise shall comply with the provisions of JB3623. The measurement of roll forging machine noise shall be carried out under idling conditions and in accordance with the single operation working specification. 5.2
The A-weighted sound power level LwA and A-weighted sound pressure level LpA of the roll forging machine noise at the specified specifications shall comply with the limits specified in Table 5. Table 5
Forging die nominal diameter Dmm
Noise at specified action specifications
A-weighted sound power level L
Noise at specified action specifications
A-weighted sound pressure level L
6 Inspection rules
≤250
6.1 The inspection categories of roll forging machines include factory inspection and type inspection. 6.1.1 Factory inspection
≤1000
Each roll forging machine shall be inspected by the quality inspection department before leaving the factory. Only after passing the inspection can it leave the factory. In special cases, with the consent of the user, the acceptance can also be carried out at the user's factory.
6.1.2 Type inspection
Type inspection must be carried out for new products and updated products (including those that may affect performance due to changes in structure, materials, and processes). 6.2
The inspection of roll forging machines shall comply with the provisions of Table 6. Table 6
Inspection items
Basic parameters and dimensions
Idle running test
Load test
Overload test
Sound power level
Sound pressure level
Center distance adjustment
Angle adjustment
Axial adjustment
Hydraulic system cleanliness
Assembly quality
Parts processing quality
Insulation test
Withstand voltage test
Protection circuit continuity test
Inspection category
Factory inspection type test
Technical requirements
Comply with the provisions of Article 3.8
Comply with the provisions of Article 4.2
Comply with the provisions of Article 4.6
Comply with the provisions of Article 4.3
Comply with the provisions of Article 4.4
Comply with the provisions of Article 4.5
Comply with the provisions of Chapter 5
Comply with the provisions of Article 4.3.11
Comply with the provisions of ZBJ62001
Comply with the provisions of Article 3.6
Comply with the provisions of Article 3.6
Comply with the provisions of Article 3.7.5
Note: ① "+" indicates the items to be inspected: "_" indicates the items that may not be inspected. ②Other inspection items shall be in accordance with the provisions of this standard. Test method
Visual inspection or direct measurement
Direct measurement
Inspect according to accuracy standards
Direct measurement and visual inspection
Direct measurement and visual inspection
Direct measurement and combined measurement
Inspect according to JB3623
Direct measurement
According to the supplementary provisions of ZBJ62C01
Direct measurement and visual inspection
Inspect according to the method of GB5226
Packaging, marking and transportation
JB/T2403.3—96
7.1 The exposed machined surfaces of roll forging machine parts, components and accessories shall be coated and sealed for protection before packaging, and the anti-rust requirements shall comply with the provisions of ZBJ50013.
7.2 The packaging of roll forging machines and their parts and components shall comply with the provisions of ZBJ50014. 7.3 The relevant storage and transportation instructions and signs shall comply with the provisions of GB191. 7.4 The basic contents of product markings shall include the following: a. Manufacturer name:
b. Product model, name, specifications:
c. Main technical parameters of the product:
d. Factory number;
e. Factory date.
5 The basic contents of packaging markings include the following: 7.5
a. Shipping and transportation marks include: manufacturer name, product name and model, shipping location, receiving station name, receiving unit and gross weight, volume, etc.
b. Transportation operation signs include: Handle with care, center of gravity lifting line and rain and moisture protection, etc. Random technical documents
Each roll forging machine should be provided with the following technical documents: a. Instruction manual;
b. Certificate of conformity:
c. Packing list.
JB/T2403.3—96
Appendix A
Conditions for load test and overload test of roll forging machine (reference)
Square section test pieces are used, and the size should meet the forgeable rough size specified in the roll forging machine parameters. The rolling length L is not less than 0.35D (D is the nominal diameter of the forging die). Flat die rolling is adopted, and the pressure is calculated according to the material of the specimen, the rolling temperature and the size of the specimen after rolling according to formula (A1): p=bmJRAhk,[1+(1.6u/RAh-1.2Ah)/(H+h)) where: p
rolling force, N;
average width of the specimen, bZxz.net
b ==(B+ b):
Width of specimen before rolling, mm;
Width of specimen after rolling, mm;
Radius of flat die surface, mm:
Amount of reduction, Ah=Hh;
Height of specimen, mm;
Height of specimen after rolling, mm
Deformation resistance, k=k+2nv△h/R/(H+h);Compression strength, k=(1-0.01t)(1.4+C+Mn):Rolling temperature, ℃;
Viscosity coefficient, 7=0.01(14-0.01t);Carbon content of material, %;
Mn-manganese content of material, %
Number of revolutions per minute of forging roller, r/min;
Circumferential speed of roller, V=
Friction coefficient, u=1.05-0.005t.
During the overload test, the rolling temperature is reduced, and other conditions remain unchanged. A4
Additional Notes:
This standard is proposed and managed by Jinan Foundry and Forging Machinery Research Institute. This standard is drafted by Guiyang Forging Machinery Research Institute. The main drafters of this standard are Liu Qingan and Lei Qixiang. (A)
Mechanical Industry Standard
Technical Conditions for Roll Forging Machine
JB/T2403.3-96
Published and issued by the China Academy of Mechanical Science
Printed by the China Academy of Mechanical Science
(No. 2 Shouti South Road, Beijing, Postal Code 100044)*
Format 880×12301/16 Printing Sheet 3/4
4 Word Count 14.000
First Edition in October 1996 First Printing in October 1996 Print Quantity 00,001-500
Price 10.00 Yuan
No. 96-028
Mechanical Industry Standard Service Network: http/AvwwJB.ac.cn96
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