Dalian is proud of China people.
On the morning of February 29th, 2007, the first large-scale marine crankshaft 65438 independently developed by Dalian Huarui Marine Crankshaft Co., Ltd., which is controlled by Dalian Heavy Industry Lifting Group, officially rolled off the assembly line. It is 6.7 meters long and weighs 4 1 ton. It requires high-precision machining, and the vibration amplitude during rotation cannot be greater than one-fifth of the human head hair.
On July 27th, 2008, the longest and heaviest marine crankshaft in China rolled off the production line at Shanghai Electric Lingang Heavy Equipment Base. This is the first crankshaft of 8K90MC-C marine high-power low-speed diesel engine in China, with a total length of 16m and a weight of about 200 tons, which fills a gap in China. It also marks that Shanghai Electric has taken the lead in manufacturing large-diameter marine crankshafts in China.
Following this latest achievement, in 2009, Shanghai Electric Heavy Industry Group will trial-produce super-large advanced products such as 12K98MC-C crankshaft with the largest model specifications in the world according to the needs of overseas users. Liu Chaoming, general manager of Shanghai Marine Crankshaft Company, said that with the accumulation and maturity of technology, China shipbuilding industry is expected to break? One axis is hard to find? Subject to the bottleneck of people, promote our country from? A big shipbuilding country? Where to? Shipbuilding power? Take a quick step forward.
Create a Chinese core
Crankshaft, as a key component of marine engine, is known as the "heart" of marine diesel engine and plays a vital role in the safety of ships. Crankshaft for large ships is required to have the same service life as the ship and be maintenance-free for life. The service life is generally more than twenty or thirty years, accounting for one-third of the total cost of the engine. But China's shipbuilding industry has lacked this piece for decades? China heart? . Because of its heavy weight, high machining accuracy and difficult manufacturing technology, the term "crankshaft manufacturing capability" is commonly used in the industry, which represents the shipbuilding industry level of a country to a certain extent. At present, Japan, South Korea, Czech Republic, Spain and a few other countries with the ability to manufacture semi-assembled crankshafts for large ships have highly monopolized the international market for large marine crankshafts.
An important advantage of shipbuilding industry in South Korea and Japan is the high occupation rate of crankshaft. In view of this, Shanghai Crankshaft Company plays a very important role, which is not only a breakthrough to solve the problem of insufficient production capacity of supporting products for high-power marine main engines, but also a breakthrough in shipbuilding output in China. Eleventh five-year plan? Occupy more than 25% of the world market share by the end of the year.
Because a few countries completely monopolize the global crankshaft, after 200 1, China's shipbuilding industry often encounters the situation that the crankshaft is twice or twice as high as before. Diesel engine manufacturers can't produce diesel engines without ordering crankshafts, and shipyards can't take orders for ships without buying main engines, resulting in? Fifteen? During this period, millions of tons of overseas shipbuilding orders were abandoned. At an international order meeting, several Japanese and Korean crankshaft suppliers joked with the head of a domestic marine diesel engine factory that drinking a large glass of white wine would sell a crankshaft. Without saying anything, the person in charge raised his glass, which scared the suppliers to applaud again and again, because the crankshafts they produced would be given priority to supply to their own countries, and they did not dare to promise to domestic customers easily.
With the rising cost of raw materials and the soaring demand of other countries, the price of each marine crankshaft has reached more than 500 thousand dollars. The lack of independent manufacturing capacity of this key component once restricted the development of shipbuilding industry in China, and made China pay a high price while winning the title of "the third shipbuilding country in the world". Statistics show that from 1978 to 1997, China spent more than 90 million dollars on imported crankshafts. In recent years, due to the soaring price of crankshafts, the demand for crankshafts in China shipbuilding industry is increasing day by day, and the annual cost of importing crankshafts has reached 40-50 million US dollars. In recent years, the contradiction between supply and demand of semi-assembled crankshaft is more prominent, the price is rising year by year, and the delivery time is often not guaranteed. Therefore, it has become a strategic task in China's economic construction to quickly establish our own crankshaft production base and realize the localization of marine high-power low-speed diesel engine crankshaft.
Color development method
Around 200 1, it is a new expansion period of the world shipbuilding industry, and the demand for large high-tech value-added ships in various countries has surged. The low self-made level of marine auxiliary equipment is not commensurate with China's status as a big ship producer, especially the embarrassing situation that the crankshaft, the core component of marine diesel engine, cannot be self-sufficient, which is the background of the birth of Shanghai marine crankshaft.
In order to change the present situation of China's shipbuilding industry, in 200 1 year, under the relevant instructions of national leaders, the National Development and Reform Commission approved the localization project of semi-assembled crankshaft for ships, and arranged some national debt funds to support it.
In May 2002, Shanghai Electric (Group) Co., Ltd., Hudong Zhonghua Shipbuilding (Group) Co., Ltd., China Shipbuilding Industry Corporation and Shanghai Industrial Investment Company jointly established Shanghai Marine Crankshaft Co., Ltd., with an investment of 654.38+86 million yuan to carry out scientific and technological research on marine semi-assembled crankshafts.
Technical difficulties
On the surface, the crankshaft is just a part that is more than ten meters long and weighs dozens of tons. Iron pimple? . However, its design and manufacturing process is quite complicated.
Crankshaft is a direct connection between diesel engine and transmission shaft, which is used to transmit propulsion. It is made of forged steel, which is made by melting and casting steel and cast steel in a mold. Generally speaking, there are two manufacturing methods. One is the integral manufacture of crankshaft, which is mainly used for medium and high-speed diesel engines for small and medium-sized ships and power generation. This kind of crankshaft has long been self-sufficient in China, and the other is an assembled crankshaft, which is mainly used in large and medium-sized ships and low-speed two-stroke diesel engines for power generation. It is a combination of crankshaft and journal. This kind of crankshaft didn't achieve zero breakthrough until 2005 in China.
There are two manufacturing methods of assembled crankshafts: forging and casting. Forging method needs press and other equipment, so the cost of gas cutting and machining is high and the manufacturing cost is high. However, because it is processed by a press, the fatigue strength can be improved. Compared with forging method, casting method has advantages in cost and can be mass produced, but its fatigue strength is lower than forging method. At present, there are two domestic enterprises producing crankshaft blank forgings, namely Angang Heavy Machinery and Zhong Yi Group.
The crankshaft of marine high-horsepower low-speed diesel engine is complex in shape and bears alternating load, so it is not allowed to be replaced during the life of the ship. Therefore, there are high requirements for the purity, strength and hardness of crankshaft steel, and high requirements for the strength, fatigue resistance and impact resistance of crankshaft blank forgings. Moreover, the integral forming process of crankshaft blank is complex, and forging manufacturing must also obtain international manufacturing license and classification society factory license.
On June 7, 2007, 65438+February 7, Angang Heavy Machinery Co., Ltd. officially accepted the Danish-B&; W headquarters? Manufacturing certificate of crankshaft forgings for large marine diesel engines? This shows that Angang has become the first enterprise in China to apply for the certification of six classification societies to produce crankshaft forgings for large marine diesel engines. Angang Heavy Machinery Co., Ltd. began to develop the forging of crankshaft blank of high horsepower diesel engine in May 2006. Using advanced vacuum smelting and vacuum casting technology, the pure smelting and casting of crankshaft steel were successfully realized, and the steel reached the requirements of crankshaft steel standard. By using computer simulation technology, the bending die, forging process and heat treatment process of crankshaft handle are optimized, and the crankshaft blank is forged successfully.
From August to September, 2007, Zhong Yi Group successively obtained the factory accreditation certificates from China Register of Shipping and Lloyd's Register of Shipping. 10 year128 October officially received the "manufacturing license for crankshaft forgings of large marine diesel engines" from Danish B&: W headquarters. So far, Zhong Yi Group has obtained all the certifications of crankshaft blanks with production specifications below 80, and has the qualification of crankshaft forgings for large marine diesel engines. Zhong Yi Group is currently actively developing MANB & amp； W and Waxilan -NSD (Waxilan) are two types of 90-class crankshafts, which are expected to be certified in the first half of 2008 and recognized by more than six classification societies. By then, Zhong Yi Group will have the qualification to produce marine crankshaft blank forgings at all levels. After the technical transformation of crankshaft industrialization, Zhong Yi Group has an annual production capacity of 75 crankshaft blanks in 2008.
The first crankshaft of Shanghai Crankshaft Company was originally planned to roll off the production line in June 2004, but it was postponed to 20051October 65438+ due to new problems in the development process. On June 5438+ 10, 2005, the first domestic semi-assembled crankshaft of high-power and low-speed marine diesel engine was successfully rolled off the production line in Shanghai Marine Crankshaft Co., Ltd. This semi-assembled crankshaft of marine diesel engine with a length of 7.5 meters and a weight of about 60 tons achieved a zero breakthrough in this field in China. The birth of this crankshaft is the biggest technological breakthrough in the supporting field of China shipbuilding industry during the Tenth Five-Year Plan period.
In order to upgrade the technology, the company widely absorbs the crankshaft blank manufacturing and crankshaft processing technologies at home and abroad, and adopts? Industry-University-Research? The technological innovation mode of strategic alliance and joint research has embarked on a development road of combining Industry-University-Research, independent innovation and independent development, made great breakthroughs in crankshaft materials, bending and forging technology, crankshaft red sleeve technology, crankshaft finishing technology and many other aspects, mastered the key technologies in the crankshaft manufacturing process, and formed a number of crankshaft core manufacturing technologies with independent intellectual property rights. Among them, advanced crankshaft red sleeve technology, crankshaft finishing technology of special crankshaft machine tool with rotary tool rest, design and application of wide-edged cutter, Diesel engine? Crankshaft? Ship shafting? Propeller system? The difficulty of tackling key problems in dynamic analysis has reached the level of similar products in the world. By the end of February 2006, the company had applied for national patents 10, including 3 utility model patents and 7 invention patents. At present, the company has undertaken a total of 52 sets of marine crankshafts 100 (including 96 sets exported). In 2007, more than 50 sets have been completed, and it is planned to produce100 sets in 2008.
The data show that by 20 10, China will need about 3 10 semi-assembled crankshafts for large ships, and it will reach 473 in 20 15. By then, the global large-scale marine semi-assembled crankshaft will still be in short supply. In order to quickly form an industrial scale, Shanghai Electric Group made a timely decision to start the second phase of crankshaft construction in Lingang heavy equipment manufacturing base. It is reported that the company invested 592 million yuan in the second phase of crankshaft project, built a new workshop of about 24,000 square meters, and added 32 sets of special equipment such as crankshaft lathe and crankshaft vertical lathe, forming an annual production capacity of 200 crankshafts.
It is revealed that by 20 10, Shanghai Marine Crankshaft Co., Ltd. will achieve an annual output of 240 large-scale semi-assembled crankshafts, ranking among the top three crankshaft manufacturers in the world; By 20 15, it is planned to keep the crankshaft product quality, production capacity and enterprise brand number one in the world.
At present, only three domestic enterprises can produce crankshafts of large ships. Details are as follows.
Shanghai Marine Crankshaft Co., Ltd. produced 40 crankshafts in 2007, which not only broke the monopoly of a few countries such as Japan and South Korea on technology and market, but also completed the export of half of the products. With the commencement of the second phase of the project, the output in 2008 will triple that of last year, reaching 120. At present, the company has undertaken a total of 52 sets of marine crankshafts/KLOC-0 (96 of which are exported). In addition, it is planned that the output will be 65,438+060 in 2009 and 200 in 2065,438+00, which is almost the same as that of the marine main engine crankshaft factory under Doosan Heavy Industry of Korea. Doosan Heavy Industry produced 200 crankshafts in 2004 and 220 crankshafts in 2005. Since the output increased to 270 vehicles in 2006, there are no reports of any plans to expand production.
Qingdao Haixi Heavy Industry Co., Ltd. has produced 15 crankshafts since it produced the first crankshaft in May last year, forming an annual assembly and processing capacity of 50 semi-assembled crankshafts. After the second phase of the project is completed and put into production, it will form an annual output of 150 large marine diesel engine crankshafts, and its first marine crankshaft was successfully rolled off the assembly line in May last year.
Dalian Huarui Crankshaft Company has formed an annual production capacity of 40 crankshafts, and its production capacity will reach 75 crankshafts by 2009. At present, the company has 63 contracts for large marine spindles, with 23, 38 and 2 in the next three years, and the order intention reaches 58.