原文：
福州仪器阀门厂根据生产发展的需要，计划建立一条球阀球体加工生产线，鉴于本厂目前没有完善的不锈钢球体铸、锻设备（市区不允许有影响城市环境的生产设备），球体毛坯均依靠外协加工，不但费用高，质量不稳定，而且交货期不能保证，影响了正常的生产。并且这两种方法得到的毛坯存在加工余量大，材料利用率低，特别是铸造球体存在毛细孔漏气等缺点，导至产品成本高， 质量难以稳定等，严重影响本厂的生产发展。因此，对球体加工技术的改造势在必行。 1、球体旋压的原理 1.1、阀门球体技术参数（见表一） 球体技术参数 1.2、球体成形方法比较 （1）铸造法 这是一种传统的加工方法，它需要一套完善的熔炼、浇注等设备，还需要较大的厂房和较多的工人，投资大，工序多，生产工艺复杂，并污染环境，每道工序的工人技术水平直接影响产品的质量，球体毛细孔渗漏的问题尚无法彻底解决，而毛坯加工余量大，浪费大，往往在加工过程中发现因铸造缺陷使其报废，至使产品成本增高，质量无法保证，此法本厂不宜采用。 （2）锻造法 这是目前国内许多阀门企业所采用的另一种方法，它有二种加工方式：其一是用圆钢切断加热锻打成球形实心毛坯，然后进行机械加工。其二是将下料成圆形的不锈钢板在大型压力机上模压成形，得到空心半球形毛坯，然后再对焊成球体毛坯进行机械加工，此法材料利用率较高，但需一台大功率的压力机和加热炉以及氩孤焊设备，预计投资需要300万元才能形成生产力，此法也不适合本厂的情况。 （3）旋压法 金属旋压法是一种先进的少、无切屑加工方法，属于压力加工的新分支，它综合了锻、挤、轧及滚压等工艺特点，具有材料利用率高（可达80-90%），节省大量的加工时间（1-5分钟成形），经旋压后材料强度可提高一倍。由于旋压时，旋轮与工件小面积接触，金属材料得于二向或三向压应力状态，易于变形，在较小的动力下，就可获得较高的单位接触应力（可达25-35Mpa），因此，设备重量轻，所需总功率小（不到压力机的1/5-1/4），现已被国外阀门行业公认为是一种节能的球体加工工艺方案，同时也适用于加工其它空心回转体的零件。 旋压技术在国外已得到广泛的应用和高速的发展，工艺和设备均十分成熟和稳定，并实现机、电、液一体化的自动控制。目前，旋压技术在我国也得以较大的发展，已进入推广实用的阶段。 2、旋压球体毛坯的技术条件 根据本厂生产需要并结合旋压变形特点，拟定如下技术条件： （1）旋压毛坯材料和型式：1Gr18Nr9Tr、2Gr13的钢管或钢板； （2）旋压球体毛坯形状结构（见图1）： 3、旋压成形方案 球体旋压因所选用毛坯型式不同，效果也不相同，经分析可用二种方案： 3.1、钢管缩颈旋压法 此方案分为三步：{dy}步是将钢管根据尺寸切断后，夹在旋压机床主轴夹盘中随主轴一起旋转，旋轮借助于液压仿形装置对管坯进行若干次旋压，使其逐渐缩径收口（见图2），形成半圆球体；第二步将已形成的球体部份切下，并加工焊接坡口；第三步将二个半球体用氩孤焊对焊成所需的空心球体毛坯。 钢管缩颈旋压法方法的优点：不需要模具，成形工艺较简单；缺点是：需要用特定的钢管，有焊缝、且钢管成本较高。 3.2、钢板普旋法 此方案有二种方式：{dy}种方式将 平板圆形材料利用尾座液压的顶力，紧压在球形芯模的外端面上，同主轴一起旋转，利用液压仿形装置，经若干次旋压使平板逐渐地收缩变形贴附在芯模上（见图3），得到一个空心半球体，然后切去多余毛边并加工焊接坡口，后将二个半球体用氩孤焊对焊成所需的空心球体毛坯。 第二种方式同样用平板毛坯普旋，所不同的是旋成半球形后，还需要旋出一段呈圆柱形的半成品见图4(a)，然后将半成品毛坯装在内半球形的芯模中，利用与通径相同的尾座顶杆压紧，进行与钢管缩颈相同的旋压法，将圆柱段逐渐缩旋（收口）形成另一半球，并将收口多余的金属材料贴在顶杆上，{zh1}切掉多余部分，以获得一个所需的整体空心球毛坯见图4(b）。 钢板普旋法的此法优点：钢板来源方便、价格与钢管对比价格较低，能实现完整的空心结构球体。与钢管缩颈旋压法前面方案对比，缺点是需要二个芯模，旋压工艺复杂，所需旋压设备结构和控制均较复杂，设备造价较高，但从经济效益和产品质量方面来分析，此方案仍是{zj0}方案。 4、旋压机床的选取 该旋压机床由机、电、液三部分组成，是较先进的机电液一体化较先进的中型机床。机床示意原理。它由主轴变速箱和液压顶出器、尾座、旋轮架、床身等部分组成。 在液压传动方面，有一个液压站及其液压系统，它为机床提供除主轴旋转之外的所有动力。旋轮横向为旋压仿形控制装置，包括仿形阀，仿形板、调整机构及支架等。 在电控方面采用先进的计算机自动控制，实现旋压过程的自动化。 5、结论 上述各种加工方案的比较表明，用平板旋压的球体毛坯是一种{zj0}方案，不论在工艺上，还是在产品质量上都达到预期的效果。但任何事物都有它的两面性，平板旋压球体工艺复杂，所需旋压设备结构和自动控制均有较高的要求，局限了它的推广。

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译文：
Fuzhou instrument valve plant based on production development, planning to build a production line ball valve, as there is no perfect factory cast stainless steel ball, forging equipment (not allowed to affect the urban environment, urban equipment), all rough sphere relying on contract manufacturing, not only the high cost, unstable, and can not guarantee delivery time, affecting the normal production. And the existence of two methods of rough large machining allowance, material use is low, especially in the sphere there is capillary leakage and other casting defects, leading to high product cost, quality, stability is difficult to seriously affect the development of factory production. Therefore, processing technology, the sphere must be enforced. 1, the principle of spinning sphere 1.1, ball valve technical parameters (see Table 1) Table 1: Technical parameters of the sphere Ball Specifications 1.2, the sphere forming Comparison (1) casting This is a traditional processing methods, it requires a complete melting, casting and other equipment, but also a larger plant and more workers, invest in large, process more complex production process, and pollute the environment, each process skill level of workers directly affected the quality of products, the problem of leakage pores sphere could not be completely resolved, and large rough machining allowance of wastage, often found in the process of casting defects due to retirement, to increase the product cost quality can not guarantee that this method is not appropriate factory. (2) forging method It is currently used in many valve companies another way, it has two processing methods: one is round cut solid heat forged into spherical blanks, and then machining. The second is to feed into the next round of the stainless steel plate on the compression molding press at large, are hollow hemispherical blank, and then welded blanks for machining into a sphere, this method is relatively high material utilization, subject to a high-power The press and the furnace and the argon arc welding equipment, estimated investment needs three million yuan to the formation of productivity, this method is not suitable for our work. (3) spinning Metal spinning is a little advanced, non-chip processing methods, the new branch is pressure processing, which combines the forging, extrusion, rolling and rolling and other technological features, with high utilization ratio (up to 80-90% ), save a lot of processing time (1-5 minutes forming), strength of materials by post-spinning can be doubled. Since spinning, the spinning roller and a small area of contact with the workpiece, the metal material obtained in two or three to stress to the state, easy to deformation, the driving force in the smaller, the unit can get a higher contact stress (up to 25 - 35Mpa), therefore, equipment weight, the total power required for small (less than press 1/5-1/4), the valve industry has been recognized by foreign energy sphere is a processing program, but also applicable to other hollow rotary machining of parts. Spinning technology has been widely used abroad, and high-speed development, technology and equipment are very mature and stable, and to achieve mechanical, electrical and hydraulic control integration. At present, the spinning technology in China has also been considerable development, has entered a practical stage of promotion. 2, the technical conditions of spinning ball blank According to factory production combined with spinning deformation need to draw the following technical conditions: (1) spinning rough material and type: 1Gr18Nr9Tr, 2Gr13 of steel or steel; (2) spinning ball rough shape of the structure (Fig.1): 3 Spinning program Rough due to the use of spinning ball is different, results varied by the analysis program can be two kinds: 3.1, tube necking spinning This program is divided into three steps: The first step is to cut off steel pipe according to size, caught in the spinning spindle with spindle with rotating clip tray, the roller tube by means of hydraulic copying device on for a number of spinning, so that shut up gradually reducing diameter (see Figure 2), forming semi-circular ball; the second step will be sphere has become part of cut and machining groove; the third step will be two hemispheres welded with argon arc welding as required rough hollow sphere. Steel necking spinning method: do not die, forming process is relatively simple; disadvantage: the need to use a specific pipe, a weld, and higher steel costs. 3.2, Plate Spinning Method This program has two ways: The first way round materials using tailstock hydraulic flat top edge, pressed in the spherical surface of the outer end of the core modules, together with the spindle rotation, using hydraulic copying device, by the number of spin pressure to gradually shrink deformation plate affixed to the Core Module (see Figure 3), get a hollow hemisphere, and then cut away excess flash and groove welding process, after two hemispheres welded by argon arc welding into the hollow sphere be rough. Figure 3 plate spinning hemisphere map The second method used the same flat blank Spinning, the difference is that after rotating into the hemisphere, but also spin out of a cylindrical semi-finished products were shown in Figure 4 (a), and then loaded semi-rough hemisphere, including the core module , the utilization of the same diameter Tailstock mandril compression, carried out with the same spinning tube necking will gradually reduce rotating cylindrical section (shut up) to form the other hemisphere, and shut the excess metal material attached to the top pole, and finally cut off the excess part of the overall requirements to obtain a hollow billet Figure 4 (b). Figure 4, plate spinning hollow sphere map the whole Spinning plate method advantages of this method: steel source convenience, price comparison and steel prices lower, hollow structure to achieve a complete sphere. And steel necking spinning in front of the program compared drawback is the need of two core modules, spinning complex process, the necessary structure and control of spinning equipment than complex, high equipment costs, but economic efficiency and product quality aspects analysis, this option is still the best option. 4, the selection of spinning machine The spinning machine by the mechanical, electrical, hydraulic three parts, is more advanced mechanical and electronic integration of the more advanced mid-sized machine. Machine indicated principle (see Figure 5). It consists of spindle gearbox and hydraulic eject device, tailstock, roller frame, bed components. Figure 5 Schematic diagram of spinning machine In terms of hydraulic transmission, hydraulic station and a hydraulic system, which serves as the machine tool spindle power than all. Transverse profile for the spinning wheel spin control devices, including the profiling valves, profile board, adjustment and support such organizations. Electric control area in the use of advanced computer control to achieve spinning process automation. 5, Conclusion The comparison of the various processing programs that use the flat blank is a spinning sphere best, regardless of craft, both in product quality or achieve the desired effect. However, everything has its two sides, plate spinning sphere complex process, the necessary structure and control of spinning equipment requirements are relatively high, limited its promotion.