KHLLP supplies 800 kJ crankshaft forging machine for large diesel engines, trucks, locomotives, ships
Industrial technologies often develop at different rates depending on the requirements of the regional market; for example, investment in new ring plants has increased markedly in North America and Europe. Chinese counterfeiters worked to keep up with industrial demand on several fronts. The Chinese market for commercial vehicles does not attract as much attention as comparable demand for automotive products, but nevertheless, the demand is great. Recently, KHLLP signed a contract to develop a new hammer mill for the production of large crankshafts for trucks, locomotives and ships. It is rated at 800 kJ and will be one of the largest impact hammers developed by KHLLP, and the largest of all it has supplied to a Chinese manufacturer.
In a hammer mill with a shock impact, two forging cylinders of the same mass are used, which move synchronously to each other, achieving optimal speed at the point of impact with the workpiece. The counter-shocks of the pistons are displaced, and the force of their impact is transmitted to the workpiece, not to the base of the hammer.
Hammer presses are among the first examples of forging technology on an industrial scale, but the first hammer machine was attributed to Bêché & Grohs in 1932. Today, the Bêché product line is part of the KHLLP group, which emphasizes that the high impact energy and the tonnage of the hammer dies moving in opposite directions allows for high precision stamping of large parts.
Hammers with hydraulic drives are particularly suitable for medium-duty production (no need to design and install a complex compressed air system), and KHLLP DG series machines use pneumatic drives: this approach allows very high levels of forging energy to be achieved, and the rigid design of the vertical struts together with a reliable guide system ensures high precision in forging parts.
Of course, crankshafts are designed with special attention to geometry, as well as to the distribution of mass and weight, so high precision in forging is required. In addition, the size of the parts produced is not a significant factor in the choice of the machine: the latest developments for diesel engines emphasize high fuel economy and low emissions, which contributes to the «long stroke» to reduce the speed. In turn, this emphasizes the need for large crankshafts for heavy duty applications that can withstand high loads and withstand high loads.
The sharper adds that its hammer-on design guarantees high availability and reduced maintenance requirements.
The finished machine bêché DG80h will weigh approximately 650 metric tons, lifting more than 7 meters (23 feet) above the ground. KHLLP noted that this is the only company in the world that produces impact machines of this size.
The developer will manufacture various elements of the new machine at its workshops in Germany by mid-2017, and then complete the Assembly at the Chinese site, and production will begin in early 2018.