JB/T 6053-1992 Calculation method of fuel consumption quota for hot forging process of steel forgings
Some standard content:
Machinery Industry Standard of the People's Republic of China
Hot forging process of steel forgings
Calculation method of fuel consumption quota
1 Subject content and scope of application
This standard specifies the steel forgings Calculation method of fuel consumption quota for hot forging process. 92 | | tt | | JB/T 6053 | tt | 3.1.2 Hot forging process fuel consumption quota
According to the hot forging process regulations, the fuel consumption rating required to complete the forging production of forgings. 3.1.3 Planning statistical period
The time unit used by enterprises and workshops to plan and record production conditions within a period of time, which can be weeks, months, quarters, years, etc. Other relevant terms should comply with the provisions of GB8541. 3.2 Symbol
The symbol used in the calculation formula of this standard: B.
The fuel heat consumed when using the free forging process to produce forgings during the planned statistical period, kl: B.-Used during the planned statistical period The fuel heat consumed when producing forgings by the die forging process, kJ; 6-The amount of standard coal consumed per unit of forging production, kg/.; f
The average specific heat capacity of the heated metal at the furnace temperature, kJ/( kg·C); H
G
The average specific heat capacity of the heated metal at tu temperature, kJ/(kg·C); ·Heating furnace average load coefficient;
Heating furnace Average load rate, %;
Output of free forgings during the planned statistical period, kg or t; m—Output of die forgings during the planned statistical period, kg or t: Unit weight of free forgings produced during the planned statistical period, kg, gz. -
g
gre
Unit weight of die forgings produced during the planned statistical period, kg: fire consumption, flash, skin, The total fire loss of the core material, jaws, bottom of the steel ingot, and bone mouth, etc., kgg.-The amount of fire loss (burning loss) when the metal is heated, kgg2--
The weight of the forgings with skin during the production process, kg; The Ministry of Mechanical and Electronic Industry of the People's Republic of China approved the implementation on 1993-07-01 on 1992-05-01
297
g3-
-
· Feida during the forging production process Weight, kg; weight of operating jaws when producing forgings, kg; g
g: -—— Weight of cut-out riser of steel ingot, kg, ge
GH
Gz||tt| |-The weight of the bottom of the removed steel ingot, kg;
JB/T 6053-92
Amount of hot steel ingot (bad) used during the planned statistical period, kg; average unit weight of free forgings, kg,
-Average unit weight of die forgings, kg;
Gmp
Gj
g
H,
K
during the planned statistical period Output of alloy steel forgings produced, kg: unit weight of alloy steel forgings produced during the planned statistical period, kg; when the heating equipment is started for the hth heating equipment during the planned statistical period, h number of forgings produced during the planned statistical period, pieces; K. The number of heating fires required for the production of a single forging during the planned statistical period, times; the average number of heating fires required for the production of all forgings during the planned statistical period, times; n
m
P||tt| |Qw
The number of heating furnaces used during the planned statistical period, units; die forging production coefficient;
low fuel calorific value, kJ/m or J/kg; S,-the i-th heating equipment Average productivity, kg/h, average temperature of the heated metal when it comes out of the furnace, C: th
w.
The average temperature of the hot steel ingot (bad) when it is loaded into the furnace, C, average unit weight of free forgings Coefficient;
W. Average unit weight coefficient of die forgings;
w,
The original value of the average unit weight coefficient of a free forging; Enhanced value of the average unit weight coefficient of a free forging: W\ .
Z fuel is converted into standard coal coefficient according to equivalent calorific value; r
fuel coefficient;
β··Heating furnace thermal efficiency coefficient
1 each time the metal material is heated The burning loss and the average loss rate during the forging process, %:...-The proportion of alloy steel forgings in the forging output, %. 4 Calculation method
4.1 Free forging
When using the free forging process to produce forgings, the fuel consumption quota (B,) is calculated according to formula (1): B,--G,n(1-μ )ctaβW,F-GHthcH4.2 Die forging
When the die forging process is used to produce forgings, the fuel consumption quota (B) is calculated according to formula (2): Bm=Gmn(l+u)ctapW,P.. .
4.3 Other hot forging processes
1
(2)
When using other forging processes to produce forgings, first judge them to be free forging, based on the characteristics of the production process. Die forging or both, and then calculate the fuel consumption quota by referring to equation (1) and equation (2). 4.4 Forging process unit forging fuel consumption
Forging process unit forging fuel consumption is calculated according to formula (3): B (or Bm)
G, (or Gu)
298||tt ||2
Qnw
(3)
JB/T 6053--92
5 in formula (1), formula (2), formula (3) Calculation and selection of parameters 5.1 G. and Gm values ??
Calculated according to formula (4) and formula (5):
Gm
5.2n value
According to formula ( 6) Calculation:
EK.
K
5.3 value
Calculation according to formula (7):
gz (or more m) +|| tt||5.4W.Value
ge
4server ee+
Select W\, W\ according to Table 1, and calculate according to formula (10): Gp
Y
The average unit weight of free forgings Gp
The original value of the average unit weight coefficient W\|| tt||What proportion of alloy steel forgings are in forging production? %
Average unit weight coefficient enhancement value\
Free forging average unit weight Gsp
t
Original value of average unit weight coefficient W\
Forging output Proportion of medium alloy steel forgings
%
Average unit weight coefficient enhancement value W\
5.5Wm value
G
(t).|| tt||g
G
×100%=
X100%
,
0.15
0. 95～1.15|| tt||60
1
30
1
After calculating Gm according to Equation (11), select according to Table 2. G
ww,w\
Table 1
>0. 15～1
0. 85~~1. 05
>60|| tt||1.1
30
>5～10
1.1~1.3
>30～60
1.2
Ghp|| tt||G.
K
≥30~60
1.1
>60
1. 25
>60|| tt||1.15
.+++.
30
.
>15
1.05~1.2
30~60| |tt||1.15
>10
1.25~1.45
≥3060
1.25
(4)
(5)| |tt||(6)
(7)
(8)
(9)
(10)
≥60||tt| |1.2
>60
1.3
(11)
299
Average unit weight of die forgings Gimp
kg||tt| |The average unit weight coefficient of die forgings W.
5.6
Q value
JB/T6053-92
Table 2
>1~2.5
1. 05~1. 15
Select according to Table 3 according to the type of fuel used in production. Fuel type
Fuel low (bit) calorific value
kJ/kg or kJ/m
Fuel coefficient α
Original
20930||tt| |1.25
Coal
0. 9~~1.05
Table 3
>26163
1.15
>2. 5-~ 6. 3
0. 85 -- 0. 95
producer gas
5 861
1.1
5861
1.0| |tt|| Note: When the low (bit) calorific value of raw coal is between 20930 and 26163kJ/kg, the α value is the arithmetic mean. 5.79 value
Select Table 4 according to the type of heating furnace used in production
furnace
Type
Heating furnace thermal efficiency, %
Heating furnace Thermal efficiency coefficient 3
5.8F value
chamber furnace
8-12
8～12
is calculated according to formula (12), according to Table 5 Select, trolley furnace
11~17
6~9
f=Gn(1+)
sH
Table 5||tt ||The average load factor of the heating furnace is
%
The average load factor of the heating furnace
5.9P value
First convert Gm into annual output and select according to Table 6. Die forging production, t
die forging production coefficient P
5.10c and cH value
≤1000
1.1～1.2
50||tt| |K100
1. 05~~1. 15
Table 6
Ring furnace
22~28
3. 5~4. 5
>50~~65
26. 3+ 15
0. 8~.0. 9
Heavy
Oil
41868
10.90
Slit furnace
13~18
5.5~7.5
0.95~1. 05
≥1 000 ~5 000 ≥5 000~10 0001≥10 000~~20 0001
1. 0~~1. 1
0.9~-1.0
According to t, amber and steel The carbon content is selected according to the arithmetic mean value in Table 7. 300
0. 8~~0. 9
15
0. 75 -~0). 85
Woran Qi
35581|| tt||0.85
Semi-continuous furnace
11~~20
5·7
12)
>65
0.8 -0.95
220000
0.7.~0.8
serial number
1
2
3
6||tt ||8
10
11
5.11
2 value
temperature
100
400||tt| |500
600
700
800
900
1000
1100
1200
1250
0.09
0.465
0.515
0.532
0.565
0.599
0.666
0.707|| tt||0.707Www.bzxZ.net
0.707
0.707
0.707
0.224
0.465
0.515
0.532||tt| |0.565
0.599
0.678
0.703
0.703
0.703
0.707
0.707
JB /T6053--92
Table 7
Carbon
0.300
0.469
0.515
0.535
0.565|| tt||0.603
0.691
0.699
0.699
0.699
0.703
0.699
prime||tt| |steel
0.540
contains
carbon
amount·
0.610
and c
specific heat capacity of carbon steel| |tt||0.473
0.523
0.535
0.573
0.603
0.691
0.691
0.691||tt ||0.691
0.695
0.695
Select according to Table 8 according to the fuel used in production and the low calorific value of the fuel. Table 8
No.
Sequence
1
2
3
4
5
6
8
9
10
11
12
2CH value
5.12
Fuel name
raw coal
washed coal
dry clean coal
anthracite
heavy oil
natural gas
natural gas||tt| |Producer gas
Producer gas
Producer gas
City gas
Coke
Physical unit
kg||tt| |kg
kg
kg
kg
m
m
ma
m
m
3
kg
Average low
Calorific value SQ
kJ/physical unit
20930
8372|| tt||26 372
26163
41868
5233
5651
6070
16744
28465||tt ||According to statistics from the workshop (or unit) forging production schedule or production ledger. 5.13 value
Press the average thermometer of the hot steel ingot (bad) into the furnace. 0.477
0.523
0.540
0.573
0.607
0.687
0.687
0.687
0.691| |tt||0.691
0.695
0.795
0.481
0.527
0.544
0.573
0.607||tt ||0.678
0.678
0.678
0.680
0.687
0.687
Equivalent mature value
kJ/actual object Unit
20930
8372
26372
26163
46046
35581
39767
8494| |tt||8694
9034
32232
33488
kj/(kg)
0.050
0.494
0.535
0.553
0.578
0.615
0.687
0.670
0.653
0.661
0.661
0.661
1.410
0.486
0.527| |tt||0.544
0.582
0.607
0.682
0.674
0.674
0.678
.678|| tt||0.678
standard coal conversion coefficient Z
0.714
0.285
0. 9
0.89
1.571||tt| |1.214
1.36
0.29
3.297
0.31
1.10
1.143
301
JB /T6053--92
6 Steel forgings hot forging process fuel consumption quota calculation step 6.1 According to the values ??provided by the forging process documents of the forgings to be produced during the planned statistical period and formulas (4) to (8), formulas (11), calculate Gz, GmGzp, Gmp, GH, P, n, μ and other values. 6.2 According to the forging heating process document, the technical parameters of the heating equipment and the pre-arrangement of the forging production plan, determine the values ????of t and t, and calculate f according to equation (12).
6.3 According to the actual fuel type used by the workshop (or unit) and its low calorific value, heating furnace type, and the value calculated in 6.1, look up the table! Determine W\W\ and calculate W according to equation (10). Check Table 2 to Table 7 as needed to determine parameter values ??such as Wmα, B, F, P, c and CH. 6.4 Substitute the determined parameter values ??into formula (1) or formula (2) respectively to calculate the fuel consumption B and Bm required to produce G (or Gm) tons of qualified forgings, that is, calculate the steel produced during the statistical period Fuel consumption quota for hot forging process of quality forgings. 6.5 Check table 8 to determine Z. Convert b and B. into unit forging fuel consumption according to formula (3). 302
JB/T 6053—92
Appendix A
Example of fuel consumption quota calculation for hot forging process of steel forgings (reference parts)
A1 is produced by free forging process Forgings
The forging workshop of a certain factory produced 12277.281 free forgings using steel ingots as raw materials during the planned statistical period (year), including 5603.18t of alloy forgings. The heating furnaces are all trolley-type heating furnaces with an average thermal efficiency of 11%. The fuel used is generator gas, which has been measured to be Q5651kJ/m2. According to the statistical analysis of relevant process documents such as the forging process card, it is known that the average number of heating fires for forgings is 1.85 times, the average loss rate of metal materials for each heating and forging is 24%, and the average weight of forgings is between 1 and 5 tons. The charging capacity of hot steel ingots is 7(000t), and the average charging temperature is 600C. The production capacity of the heating furnace is 35000t/a. Trial calculation: a. Fuel consumption quota for forging process (B.); b. Fuel consumption per unit forging (6) .
Known: G, 12 277.28t=12 277.28X103kgn=1.85 times
Certificate=24%
1=1250℃ Look up table 7, take c at 0~~1250 The average value between ℃, =0.603kl/(kg·℃) Qnw=5651kJ/m (generator gas) Look up table 3, take a=1. The thermal efficiency of the trolley heating furnace is 11%, look up table 4, take 8 =9Gp between 1～5t
Gj=5 603. 18t
G
×100%
G
5603.18
X100%=45.6%
12 277. 28
Look up table 1, take W\,--1.1,W\1.15
W.-W\W\,-1.1X1 .15=1.265
Also:
S - 35 000t
×100%=12 277,28X1:85×(1±0.24)×100%=80. 5%Gn (i+μ)
s,H,
Look up table 5, take F=0.9
GH=7 000t
35 000
th= 600℃
Look up Table 7 and take the average value of cH between 0~600℃, cH=0.526kJ/(kg·(C) according to formula (1):
B,-Gn (1+μ)ctapW,F--GhthcH
12277.28×10°×1.85×(1+0.24)×0.603×1250×1X1.265X9X0.9--7 000X10*X600X0.5262. 153 104 2X101 (kJ)
According to formula (3):
B,z
b
G.QYw
2.153104.210×0.297||tt| |12277.28×5651
= 921, 7(kg/t)
303.
JB/T6053-92
So: a. Health*: 12277.28t free The fuel consumption quota for the forging process is 2.1531042 × 10kJ (38.07 million m of gas);
b. The fuel consumption per unit forging is 921.7kg/1 (3103.1m2 gas/t forging) A2 uses the die forging process to produce forgings|| tt||The output of die forgings of a professional die forging production factory during the planned statistical period (annual) is 4019t. The heating equipment is a push rod heating furnace, and the fuel used is generator gas. According to actual measurement, Qw=5651kJ/m, the average heating of forgings The number of fires was 1. According to the forging process documents and statistical data, the average loss rate of metal materials was 23%, and the average weight of the forgings was 3.6kg. Trial calculation: a. Forging process fuel consumption quota (Bm); b. Fuel consumption per unit forging (6).
Known: Gm=4019t=4019×10°kg
nz-1 times
=23%
Look up table 7 according to the process file t1250℃, take c The average value between 2001250℃ = 0.603kJ/(kg·() The fuel is producer gas, Qw=5651kJ/m2, check Table 3, take α=1 for push rod heating furnace and select β for semi-continuous furnace, check Table 4, take β=7Gmp=36kg and look up Table 2, take Wm-0.9
Gm-4 019t Look up Table 6, take P-1.05
Qw=5651kJ/m (producer gas) Table 8, take 20.297 according to formula (2):
BmGmm(+μu)ctαpW,P
=4019×10°×1×(1+0.23)×0.603×1250×1×7 ×0.9×1.05=2.464792×101\(kJ)
According to equation (3):
B,z
bGmQw
_2. 464 792×101°× 0.297
4 019×5 651
-322. 3(kg/t)
So; a. The fuel consumption quota for the forging process of producing 4019t die forgings is 2.464792×101°kJ ( 1.3617 million m2 gas); b unit forging fuel consumption is 322.3kg/t (1085.3m2 gas/t forging). Additional notes:
This standard is proposed by the National Forging Standardization Technical Committee. This standard is proposed by the Ministry of Machinery and Electronics Industry. Beijing Institute of Mechanical and Electrical Engineering is responsible for drafting this standard. The main drafters of this standard are Li Jianhua and Di Xuejin 31
214
1.36
0.29
3.297
0.31
1.10
1.143
301
JB/T6053--92
6 Calculation steps of fuel consumption quota for hot forging process of steel forgings 6.1 According to the values ??provided in the forging process documents of the forgings to be produced during the planned statistical period and formulas (4) to (8) and (11), calculate the values ??of Gz, GmGzp, Gmp, GH, P, n, μ, etc. 6.2 According to the forging heating process documents, the technical parameters of the heating equipment and the pre-arrangement of the forging production plan, determine the values ??of t and t, and calculate f according to formula (12).
6.3 According to the type of fuel actually used in the workshop (or unit) and its low calorific value, the type of heating furnace, and the values ??calculated in Article 6.1, check the table! Determine W\W\, and calculate W according to formula (10). Check Tables 2 to 7 as needed to determine the values ??of parameters such as Wmα, B, F, P, c and CH. 6.4 Substitute the determined parameter values ??into formula (1) or formula (2) respectively to calculate the fuel consumption B and Bm required to produce G (or Gm) tons of qualified forgings, that is, calculate the fuel consumption quota of the hot forging process of steel forgings produced during the statistical period. 6.5 Check Table 8 to determine Z. Convert b and B. into unit forging fuel consumption according to formula (3). 302
JB/T 6053—92
Appendix A
Example of calculation of fuel consumption quota for hot forging process of steel forgings (reference part)
A1 Production of forgings by free forging process
During the planned statistical period (year), the forging workshop of a certain factory produced 12277.281 tons of free forgings with steel ingots as raw materials, including 5603.18 tons of alloy forged steel parts. The heating furnaces are all trolley-type heating furnaces with an average thermal efficiency of 11%. The fuel used is generator gas, and the actual measured Q5651 kJ/m2. According to the statistical analysis of the forging process card and other relevant process documents, it is known that the average heating times of forgings is 1.85 times, the average loss rate of metal materials for each heating and forging is 24%, and the average weight of forgings is between 1 and 5 tons. The hot steel ingot loading is 7000t, and the average loading temperature is 600C. The heating furnace production capacity is 35000t/a. Try to calculate: a. Forging process fuel consumption quota (B.); b. Unit forging fuel consumption (6).
Given: G, 12 277.28t=12 277.28X103kgn=1.85 times
Certificate=24%
1=1250℃ Look up Table 7, take the average value of c between 0~~1250℃, =0.603kl/(kg·℃) Qnw=5651kJ/m (producer gas) Look up Table 3, take a=1 The thermal efficiency of the trolley heating furnace is 11%, look up Table 4, take 8=9 Gp is ??between 1~5t
Gj=5 603. 18t
G
×100%
G
5603.18
X100%=45.6%
12 277. 28
Look up Table 1, take W\,--1.1,W\1.15
W.-W\W\,-1.1X1.15=1.265
Also:
S - 35 000t
×100%=12 277,28X1:85×(1±0.24)×100%=80. 5%Gn(i+μ)
s,H,
Look up Table 5, take F=0.9
GH=7 000t
35 000
th=600℃
Look up Table 7 and take the average value of cH between 0~600℃, cH=0.526kJ/（kg·（C）According to formula (1):
B,-Gn(1+μ)ctapW,F--GhthcH
12277.28×10°×1.85×(1+0.24)×0.603×1250×1X1.265X9X0.9--7 000X10*X600X0.5262. 153 104 2X101(kJ)
According to formula (3):
B,z
b
G.QYw
2.153104.210×0.297
12277.28×5651
= 921, 7(kg/t)
303.
JB/T6053-92
Therefore:a. Production*: The fuel consumption quota for the forging process of 12277.28t free forgings is 2.1531042×10 kJ (38.07 million m2 of gas);
b. The fuel consumption per unit forging is 921.7kg/1 (3103.1m2 of gas/t forging)A2 adopts die forging process to produce forgings
During the planned statistical period (year), the output of die forgings of a die forging production plant is 4019t. The heating equipment is a push rod heating furnace, and the fuel used is generator gas. The actual measurement shows that Qw=5651kJ/m, and the average heating times of forgings is 1 time. According to the forging process documents and statistical data, the average loss rate of metal materials is 23%, and the average weight of forgings is 3.6kg. Try to calculate: a. Forging process fuel consumption quota (Bm); b, unit forging fuel consumption (6).
Given: Gm=4019t=4019×10°kg
nz-1time
=23%
According to the process document t1250℃, check Table 7, take the average value of c between 2001250℃=0.603kJ/(kg·()) The fuel is the generator gas, Qw=5651kJ/m2, check Table 3, take α=1 Push rod heating furnace selects β according to the semi-continuous furnace, check Table 4, take β=7Gmp=36kg Check Table 2, take Wm-0.9
Gm-4 019t Look up Table 6, take P-1.05
Qw=5651kJ/m (producer gas) Look up Table 8, take 20.297 According to formula (2):
BmGmm(+μu)ctαpW,P
=4019×10°×1×(1+0.23)×0.603×1250×1×7×0.9×1.05=2.464792×101\(kJ)
According to formula (3):
B,z
bGmQw
_2. 464 792×101°×0.297
4 019×5 651
-322. 3(kg/t)
Therefore; a. The fuel consumption quota for the forging process of producing 4019t die forgings is 2.464792×101°kJ (1.3617 million m2 of coal gas); b. The fuel consumption per unit forging is 322.3kg/t (1085.3m2 of coal gas/t forging). Additional notes:
This standard is proposed by the National Forging Standardization Technical Committee. This standard is under the jurisdiction of the Beijing Electromechanical Research Institute of the Ministry of Machinery and Electronics Industry. This standard is drafted by the Design Institute of the Ministry of Machinery and Electronics Industry. The main drafters of this standard are Li Jianhua and Di Xuejin. 31
214
1.36
0.29
3.297
0.31
1.10
1.143
301
JB/ T6053--92
6 Steel forgings hot forging process fuel consumption quota calculation step 6.1 According to the values ??provided by the forging process documents of the forgings to be produced within the planned statistical period and formulas (4) to (8), formula ( 11), calculate Gz, GmGzp, Gmp, GH, P, n, μ and other values. 6.2 According to the forging heating process document, the technical parameters of the heating equipment and the pre-arrangement of the forging production plan, determine the values ????of t and t, and calculate f according to equation (12).
6.3 According to the actual fuel type used by the workshop (or unit) and its low calorific value, heating furnace type, and the value calculated in 6.1, look up the table! Determine W\W\ and calculate W according to equation (10). Check Table 2 to Table 7 as needed to determine parameter values ??such as Wmα, B, F, P, c and CH. 6.4 Substitute the determined parameter values ??into formula (1) or formula (2) respectively to calculate the fuel consumption B and Bm required to produce G (or Gm) tons of qualified forgings, that is, calculate the steel produced during the statistical period Fuel consumption quota for hot forging process of quality forgings. 6.5 Check table 8 to determine Z. Convert b and B. into unit forging fuel consumption according to formula (3). 302
JB/T 6053—92
Appendix A
Example of fuel consumption quota calculation for hot forging process of steel forgings (reference parts)
A1 is produced by free forging process Forgings
The forging workshop of a certain factory produced 12277.281 free forgings using steel ingots as raw materials during the planned statistical period (year), including 5603.18t of alloy forgings. The heating furnaces are all trolley-type heating furnaces with an average thermal efficiency of 11%. The fuel used is generator gas, which has been measured to be Q5651kJ/m2. According to the statistical analysis of relevant process documents such as the forging process card, it is known that the average number of heating fires for forgings is 1.85 times, the average loss rate of metal materials for each heating and forging is 24%, and the average weight of forgings is between 1 and 5 tons. The charging capacity of hot steel ingots is 7(000t), and the average charging temperature is 600C. The production capacity of the heating furnace is 35000t/a. Trial calculation: a. Fuel consumption quota for forging process (B.); b. Fuel consumption per unit forging (6) .
Known: G, 12 277.28t=12 277.28X103kgn=1.85 times
Certificate=24%
1=1250℃ Look up table 7, take c at 0~~1250 The average value between ℃, =0.603kl/(kg·℃) Qnw=5651kJ/m (generator gas) Look up table 3, take a=1. The thermal efficiency of the trolley heating furnace is 11%, look up table 4, take 8 =9Gp between 1～5t
Gj=5 603. 18t
G
×100%
G
5603.18
X100%=45.6%
12 277. 28
Look up table 1, take W\,--1.1,W\1.15
W.-W\W\,-1.1X1 .15=1.265
Also:
S - 35 000t
×100%=12 277,28X1:85×(1±0.24)×100%=80. 5%Gn (i+μ)
s,H,
Look up table 5, take F=0.9
GH=7 000t
35 000
th= 600℃
Look up Table 7 and take the average value of cH between 0~600℃, cH=0.526kJ/(kg·(C) according to formula (1):
B,-Gn (1+μ)ctapW,F--GhthcH
12277.28×10°×1.85×(1+0.24)×0.603×1250×1X1.265X9X0.9--7 000X10*X600X0.5262. 153 104 2X101 (kJ)
According to formula (3):
B,z
b
G.QYw
2.153104.210×0.297||tt| |12277.28×5651
= 921, 7(kg/t)
303.
JB/T6053-92
So: a. Health*: 12277.28t free The fuel consumption quota for the forging process is 2.1531042 × 10kJ (38.07 million m of gas);
b. The fuel consumption per unit forging is 921.7kg/1 (3103.1m2 gas/t forgings) A2 uses the die forging process to produce forgings|| tt||The output of die forgings of a professional die forging production factory during the planned statistical period (annual) is 4019t. The heating equipment is a push rod heating furnace, and the fuel used is generator gas. According to actual measurement, Qw=5651kJ/m, the average heating of forgings The number of fires was 1. According to the forging process documents and statistical data, the average loss rate of metal materials was 23%, and the average weight of forgings was 3.6kg. Trial calculation: a. Forging process fuel consumption quota (Bm); b. Fuel consumption per unit forging (6).
Known: Gm=4019t=4019×10°kg
nz-1 times
=23%
Look up table 7 according to the process file t1250℃, take c The average value between 2001250℃ = 0.603kJ/(kg·() The fuel is producer gas, Qw=5651kJ/m2, check Table 3, take α=1 for push rod heating furnace and select β for semi-continuous furnace, check Table 4, take β=7Gmp=36kg and look up Table 2, take Wm-0.9
Gm-4 019t Look up Table 6, take P-1.05
Qw=5651kJ/m (producer gas) Table 8, take 20.297 according to formula (2):
BmGmm(+μu)ctαpW,P
=4019×10°×1×(1+0.23)×0.603×1250×1×7 ×0.9×1.05=2.464792×101\(kJ)
According to equation (3):
B,z
bGmQw
_2. 464 792×101°× 0.297
4 019×5 651
-322. 3(kg/t)
So; a. The fuel consumption quota for the forging process of producing 4019t die forgings is 2.464792×101°kJ ( 1.3617 million m2 gas); b unit forging fuel consumption is 322.3kg/t (1085.3m2 gas/t forging). Additional notes:
This standard is proposed by the National Forging Standardization Technical Committee. This standard is proposed by the Ministry of Machinery and Electronics Industry. Beijing Institute of Mechanical and Electrical Engineering is responsible for drafting this standard. The main drafters of this standard are Li Jianhua and Di Xuejin 31
Converted into unit forging fuel consumption. 302
JB/T 6053—92
Appendix A
Example of calculation of fuel consumption quota for hot forging process of steel forgings (reference part)
A1 Production of forgings by free forging process
During the planned statistical period (year), the forging workshop of a certain factory produced 12277.281 free forgings with steel ingots as raw materials, including 5603.18t of alloy forged steel parts. The heating furnaces are all trolley-type heating furnaces, with an average thermal efficiency of 11%. The fuel used is generator gas, and the actual measured Q5651kJ/m2. According to the statistical analysis of the forging process card and other relevant process documents, it is known that the average heating times of forgings is 1.85 times, the average loss rate of metal materials for each heating and forging is 24%, and the average weight of forgings is between 1~~5t. The hot steel ingot loading is 7000t, and the average loading temperature is 600C. The heating furnace production capacity is 35000t/a. Try to calculate: a. Forging process fuel consumption quota (B.); b. Unit forging fuel consumption (6).
Given: G, 12 277.28t=12 277.28X103kgn=1.85 times
Certificate=24%
1=1250℃ Look up Table 7, take the average value of c between 0~~1250℃, =0.603kl/(kg·℃) Qnw=5651kJ/m (producer gas) Look up Table 3, take a=1 The thermal efficiency of the trolley heating furnace is 11%, look up Table 4, take 8=9 Gp is ??between 1~5t
Gj=5 603. 18t
G
×100%
G
5603.18
X100%=45.6%
12 277. 28
Look up Table 1, take W\,--1.1,W\1.15
W.-W\W\,-1.1X1.15=1.265
Also:
S - 35 000t
×100%=12 277,28X1:85×(1±0.24)×100%=80. 5%Gn(i+μ)
s,H,
Look up Table 5, take F=0.9
GH=7 000t
35 000
th=600℃
Look up Table 7 and take the average value of cH between 0~600℃, cH=0.526kJ/（kg·（C）According to formula (1):
B,-Gn(1+μ)ctapW,F--GhthcH
12277.28×10°×1.85×(1+0.24)×0.603×1250×1X1.265X9X0.9--7 000X10*X600X0.5262. 153 104 2X101(kJ)
According to formula (3):
B,z
b
G.QYw
2.153104.210×0.297
12277.28×5651
= 921, 7(kg/t)
303.
JB/T6053-92
Therefore:a. Production*: The fuel consumption quota for the forging process of 12277.28t free forgings is 2.1531042×10 kJ (38.07 million m2 of gas);
b. The fuel consumption per unit forging is 921.7kg/1 (3103.1m2 of gas/t forging)A2 adopts die forging process to produce forgings
During the planned statistical period (year), the output of die forgings of a die forging production plant is 4019t. The heating equipment is a push rod heating furnace, and the fuel used is generator gas. The actual measurement shows that Qw=5651kJ/m, and the average heating times of forgings is 1 time. According to the forging process documents and statistical data, the average loss rate of metal materials is 23%, and the average weight of forgings is 3.6kg. Try to calculate: a. Forging process fuel consumption quota (Bm); b, unit forging fuel consumption (6).
Given: Gm=4019t=4019×10°kg
nz-1time
=23%
According to the process document t1250℃, check Table 7, take the average value of c between 2001250℃=0.603kJ/(kg·()) The fuel is the generator gas, Qw=5651kJ/m2, check Table 3, take α=1 Push rod heating furnace selects β according to the semi-continuous furnace, check Table 4, take β=7Gmp=36kg Check Table 2, take Wm-0.9
Gm-4 019t Look up Table 6, take P-1.05
Qw=5651kJ/m (producer gas) Look up Table 8, take 20.297 According to formula (2):
BmGmm(+μu)ctαpW,P
=4019×10°×1×(1+0.23)×0.603×1250×1×7×0.9×1.05=2.464792×101\(kJ)
According to formula (3):
B,z
bGmQw
_2. 464 792×101°×0.297
4 019×5 651
-322. 3(kg/t)
Therefore; a. The fuel consumption quota for the forging process of producing 4019t die forgings is 2.464792×101°kJ (1.3617 million m2 of coal gas); b. The fuel consumption per unit forging is 322.3kg/t (1085.3m2 of coal gas/t forging). Additional notes:
This standard is proposed by the National Forging Standardization Technical Committee. This standard is under the jurisdiction of the Beijing Electromechanical Research Institute of the Ministry of Machinery and Electronics Industry. This standard is drafted by the Design Institute of the Ministry of Machinery and Electronics Industry. The main drafters of this standard are Li Jianhua and Di Xuejin. 31
Converted into fuel consumption per unit forging. 302
JB/T 6053—92
Appendix A
Example of fuel consumption quota calculation for hot forging process of steel forgings (reference parts)
A1 is produced by free forging process Forgings
The forging workshop of a certain factory produced 12277.281 free forgings using steel ingots as raw materials during the planned statistical period (year), including 5603.18t of alloy forged steel parts. The heating furnaces are all trolley-type heating furnaces with an average thermal efficiency of 11%. The fuel used is generator gas, which has been measured to be Q5651kJ/m2. According to the statistical analysis of relevant process documents such as the forging process card, it is known that the average number of heating fires for forgings is 1.85 times, the average loss rate of metal materials for each heating and forging is 24%, and the average weight of forgings is between 1 and 5 tons. The charging capacity of hot steel ingots is 7(000t), and the average charging temperature is 600C. The production capacity of the heating furnace is 35000t/a. Trial calculation: a. Fuel consumption quota for forging process (B.); b. Fuel consumption per unit forging (6) .
Known: G, 12 277.28t=12 277.28X103kgn=1.85 times
Certificate=24%
1=1250℃ Look up table 7, take c at 0~~1250 The average value between ℃, =0.603kl/(kg·℃) Qnw=5651kJ/m (generator gas) Look up table 3, take a=1. The thermal efficiency of the trolley heating furnace is 11%, look up table 4, take 8 =9Gp between 1～5t
Gj=5 603. 18t
G
×100%
G
5603.18
X100%=45.6%
12 277. 28
Look up table 1, take W\,--1.1,W\1.15
W.-W\W\,-1.1X1 .15=1.265
Also:
S - 35 000t
×100%=12 277,28X1:85×(1±0.24)×100%=80. 5%Gn (i+μ)
s,H,
Look up table 5, take F=0.9
GH=7 000t
35 000
th= 600℃
Look up Table 7 and take the average value of cH between 0~600℃, cH=0.526kJ/(kg·(C) according to formula (1):
B,-Gn (1+μ)ctapW,F--GhthcH
12277.28×10°×1.85×(1+0.24)×0.603×1250×1X1.265X9X0.9--7 000X10*X600X0.5262. 153 104 2X101 (kJ)
According to formula (3):
B,z
b
G.QYw
2.153104.210×0.297||tt| |12277.28×5651
= 921, 7(kg/t)
303.
JB/T6053-92
So: a. Health*: 12277.28t free The fuel consumption quota for the forging process is 2.1531042 × 10kJ (38.07 million m of gas);
b. The fuel consumption per unit forging is 921.7kg/1 (3103.1m2 gas/t forging) A2 uses the die forging process to produce forgings|| tt||The output of die forgings of a professional die forging production factory during the planned statistical period (annual) is 4019t. The heating equipment is a push rod heating furnace, and the fuel used is generator gas. According to actual measurement, Qw=5651kJ/m, the average heating of forgings The number of fires was 1. According to the forging process documents and statistical data, the average loss rate of metal materials was 23%, and the average weight of forgings was 3.6kg. Trial calculation: a. Forging process fuel consumption quota (Bm); b. Fuel consumption per unit forging (6).
Known: Gm=4019t=4019×10°kg
nz-1 times
=23%
Look up table 7 according to the process file t1250℃, take c The average value between 2001250℃ = 0.603kJ/(kg·() The fuel is producer gas, Qw=5651kJ/m2, check Table 3, take α=1 for push rod heating furnace and select β for semi-continuous furnace, check Table 4, take β=7Gmp=36kg and look up Table 2, take Wm-0.9
Gm-4 019t Look up Table 6, take P-1.05
Qw=5651kJ/m (producer gas) Table 8, take 20.297 according to formula (2):
BmGmm(+μu)ctαpW,P
=4019×10°×1×(1+0.23)×0.603×1250×1×7 ×0.9×1.05=2.464792×101\(kJ)
According to equation (3):
B,z
bGmQw
_2. 464 792×101°× 0.297
4 019×5 651
-322. 3(kg/t)
So; a. The fuel consumption quota for the forging process of producing 4019t die forgings is 2.464792×101°kJ ( 1.3617 million m2 gas); b unit forging fuel consumption is 322.3kg/t (1085.3m2 gas/t forging). Additional notes:
This standard is proposed by the National Forging Standardization Technical Committee. This standard is proposed by the Ministry of Machinery and Electronics Industry. Beijing Institute of Mechanical and Electrical Engineering is responsible for drafting this standard. The main drafters of this standard are Li Jianhua and Di Xuejin 31
297
12277.28×5651
= 921, 7(kg/t)
303.
JB/T6053-92
So: a. *: The fuel consumption quota for the forging process of 12277.28t free forging is 2.1531042×10kJ (38.070 million m gas);
b. The fuel consumption per unit forging is 921.7kg/1 (3103.1m2 gas/t forging) A2 adopts die forging Process production of forgings
The production of die forgings of a professional die forgings production factory during the planned statistical period (year) is 4019t. The heating equipment is a push rod heating furnace, and the fuel used is generator gas. According to actual measurement, Qw=5651kJ/ m, the average number of heating fires for forgings is 1. According to the forging process documents and statistical data, the average loss rate of metal materials is 23%, and the average weight of forgings is 3.6kg. Trial calculation: a. Forging process fuel consumption quota (Bm); b. Fuel consumption per unit forging (6).
Known: Gm=4019t=4019×10°kg
nz-1 times
=23%
Look up table 7 according to the process file t1250℃, take c The average value between 2001250℃ = 0.603kJ/(kg·() The fuel is producer gas, Qw=5651kJ/m2, check Table 3, take α=1 for push rod heating furnace and select β for semi-continuous furnace, check Table 4, take β=7Gmp=36kg and look up Table 2, take Wm-0.9
Gm-4 019t Look up Table 6, take P-1.05
Qw=5651kJ/m (producer gas) Table 8, take 20.297 according to formula (2):
BmGmm(+μu)ctαpW,P
=4019×10°×1×(1+0.23)×0.603×1250×1×7 ×0.9×1.05=2.464792×101\(kJ)
According to equation (3):
B,z
bGmQw
_2. 464 792×101°× 0.297
4 019×5 651
-322. 3(kg/t)
So; a. The fuel consumption quota for the forging process of producing 4019t die forgings is 2.464792×101°kJ ( 1.3617 million m2 gas); b unit forging fuel consumption is 322.3kg/t (1085.3m2 gas/t forging). Additional notes:
This standard is proposed by the National Forging Standardization Technical Committee. This standard is proposed by the Ministry of Machinery and Electronics Industry. Beijing Institute of Mechanical and Electrical Engineering is responsible for drafting this standard. The main drafters of this standard are Li Jianhua and Di Xuejin 31
297
12277.28×5651
= 921, 7(kg/t)
303.
JB/T6053-92
Therefore:a. Production*: The fuel consumption quota for the forging process of 12277.28t free forgings is 2.1531042×10 kJ (38.07 million m2 of gas);
b. The fuel consumption per unit forging is 921.7kg/1 (3103.1m2 of gas/t forging)A2 adopts die forging process to produce forgings
During the planned statistical period (year), the output of die forgings of a die forging production plant is 4019t. The heating equipment is a push rod heating furnace, and the fuel used is generator gas. The actual measurement shows that Qw=5651kJ/m, and the average heating times of forgings is 1 time. According to the forging process documents and statistical data, the average loss rate of metal materials is 23%, and the average weight of forgings is 3.6kg. Try to calculate: a. Forging process fuel consumption quota (Bm); b, unit forging fuel consumption (6).
Given: Gm=4019t=4019×10°kg
nz-1time
=23%
According to the process document t1250℃, check Table 7, take the average value of c between 2001250℃=0.603kJ/(kg·()) The fuel is the generator gas, Qw=5651kJ/m2, check Table 3, take α=1 Push rod heating furnace selects β according to the semi-continuous furnace, check Table 4, take β=7Gmp=36kg Check Table 2, take Wm-0.9
Gm-4 019t Look up Table 6, take P-1.05
Qw=5651kJ/m (producer gas) Look up Table 8, take 20.297 According to formula (2):
BmGmm(+μu)ctαpW,P
=4019×10°×1×(1+0.23)×0.603×1250×1×7×0.9×1.05=2.464792×101\(kJ)
According to formula (3):
B,z
bGmQw
_2. 464 792×101°×0.297
4 019×5 651
-322. 3(kg/t)
Therefore; a. The fuel consumption quota for the forging process of producing 4019t die forgings is 2.464792×101°kJ (1.3617 million m2 of coal gas); b. The fuel consumption per unit forging is 322.3kg/t (1085.3m2 of coal gas/t forging). Additional notes:
This standard is proposed by the National Forging Standardization Technical Committee. This standard is under the jurisdiction of the Beijing Electromechanical Research Institute of the Ministry of Machinery and Electronics Industry. This standard is drafted by the Design Institute of the Ministry of Machinery and Electronics Industry. The main drafters of this standard are Li Jianhua and Di Xuejin. 31
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