How to equip a workshop - important rules and recommendations. Forge. Placement of equipment and tools Organization of a workplace in a forging and welding workshop

workplace called that part of the workspace where the production equipment is located, with which a person interacts in the working environment.

Welding sites are divided into permanent and temporary. Permanent (stationary) places are intended for work that is carried out in specially equipped workshops, workshops, etc. Install the welding machine in a weatherproof environment, welding table, manipulator, exhaust hood, etc. in a well-ventilated area of at least 3 m2. It is best if the floor is concrete, and the walls of the room should not reflect welding glare, which can be dangerous to the eyes.

Fig.14 Layout of the welding booth:

1 - arc power supply; 2 - grounding; 3 - power supply starter; 4 and 5 - direct and reverse conductive wires; 6 - table; 7 - ventilation; 8 - rug; 9 - electrodes; 10 - shield; 11 – electrode holder; 12 - chair;

13 - waste box; 14 - doorway

Fig.15. Workplace of the welder

Passages between multi-station welding units and between automatic welding units must be at least 1.5 m; passages between single-station welding transformers or between welding generators, as well as passages on each side of a rack or table for performing manual welding - at least 1 m. The distance between a stationary welding unit and a wall or column should be at least 0.5 m, and the distance between a wall or column and a welding machine - at least 1 m. Passages between spot and seam (roller) welding machines with workplaces opposite each other must be at least 2 m, and between butt welding machines - at least 3 m. of the machines listed above with their backs to each other, the width of the aisles must be at least 1 m, and when located with their front and back sides to each other - at least 1.5 m.

For every stationary workplace during plasma and gas-plasma processing of metals, > 4m 2 should be removed, and when working in the cabin > 3m 2.

Zones with hazardous production factors must be fenced off, safety signs are designed in accordance with GOST 12.4.026-76*.

Depending on the dimensions of the products to be welded and the nature of the production, the welder's workplace can be located either in a special cabin, or in a workshop or directly at the assembly facility. Cabin dimensions must be at least 2x2 m 2 .

Fig.16. Contact welding booths.

The walls of the cabin are made 1.8-2 m high. For better ventilation, a clearance of 150-200 mm is left between the floor to the lower edge of the wall. As a material for the walls of the cabin, thin iron can be used, as well as plywood, tarpaulin, read with a fire retardant compound, or other fire retardant materials. The cabin frame is made from metal pipes or angle steel. The doorway of the cab is usually closed with a canvas curtain mounted on rings. Plywood and tarpaulin should be impregnated with a fire-resistant composition, such as a solution of potassium alum.

The floor in the cabin must be made of fire-resistant material (brick, concrete, cement), non-slip and non-slip, and have low thermal conductivity.

The walls are painted in light gray with paints that absorb ultraviolet rays well (zinc or titanium white, yellow crown). Painting welding shops and booths in dark colors is not recommended, as this worsens the overall illumination of the welding site.

Combined lighting should be provided for work of high and highest accuracy (I-III grade), in particular, when welding and soldering materials with a thickness of 0.06 ... 0.5 mm, when flaw detection of welds and other similar works.

For lighting workshops, it is necessary to use, as a rule, gas-discharge light sources: DRL, DRI lamps; for illumination of high workshops (up to 4 m) of a large area - fluorescent lamps. Incandescent lamps are allowed.

Cabin illumination should be at least 80-100 l.

AT industrial premises welding and assembly and welding shops, the microclimate parameters should be taken in accordance with GOST 12.1.005-88 (rooms with slight excesses of sensible heat, moderate work of categories IIa and IIb).

In the cold period of the year, the permissible microclimate parameters for works IIa and IIb are respectively equal: air temperature 17 ... 23 and 15 ... 21 0 С, relative humidity< 75%, скорость движения воздуха < 0,3 и 0,4 м/с.

The cabin is equipped with local ventilation with an air exchange of 40 m3/h for each worker. The ventilation suction must be located so that the gases released during welding pass by the welder.

Fig. 17. Exhaust hood: 1- air duct; 2-gate; 3-air inlet; 4- stamped grating; 5- visor.

When welding in closed volumes, air is extracted to the suction duct of the workshop exhaust system. It is possible to supply air under the welder's mask, equal to 110 ... 140 l / min.

Fig.18. Air inlets built into welding torches during mechanized welding in CO 2 . a, b - annular symmetric and asymmetric, respectively; V-conical perforated; d- cone-slit; ----- - suction aerosol; - - - - - shielding gas.

In the organization of welding work, the correct placement of equipment is important. Multi-station units and installations, consisting of several welding units, are located in a separate room or on the area of the general production room, fenced with permanent partitions with a height of at least 1.7 m. During operation, welding converters create noise that has a harmful effect on the human nervous system, causing a decrease in attention and decreased performance. For this reason, all welding converters must be isolated in the workshop room or taken out of the production room, fenced off from all sides and covered from atmospheric precipitation.

In stationary multi-station welding installations, the welding stations are connected to the electric welding unit through a common shield, on which the necessary measuring instruments, protective equipment, signal lights, circuit breakers and clamps for connecting the welding stations should be located. In case of single-station welding, individual shields must be provided, equipped with a voltmeter and a signal light indicating to the welder the presence or absence of voltage in the welding circuit.

Organization of the workplace forge.

Proper organization of the workplace is the basis of productive and safe work blacksmiths. The most important condition rational organization workplace is correct location equipment: it must be installed so that the distance between machines, ovens, etc. was as minimal as possible, but at the same time sufficient for free and safe service. The workplace should contain only what is necessary for work; it must be well lit, have reliable ventilation, a suffocating installation, and be kept clean and tidy. Working tools and accessories are stored on racks (serviceable separately from faulty ones).

Means of mechanization of heavy and labor intensive processes facilitating working conditions and increasing its productivity. Forging shops, if necessary, should be provided with powerful overhead cranes with two hooks (for the main and auxiliary lifts), slewing cranes cantilever type, tilters, forging manipulators, etc. The workplace must meet the requirements of labor safety - exhaust hoods are installed above the furnaces, dangerous places fence.

Before starting work, the foreman must accept the workplace clean and in perfect order from the shift, check the condition of the equipment and tools and, in case of a malfunction, immediately inform the foreman about this. As a rule, those working in the previous shift are required to bring blanks to the workplace and load them into the furnace in such a way that by the start of work new shift they were heated to forging temperature. The blacksmith should not leave the workshop without waiting for the shift and without transferring the workplace to him.

Safety.

Workers must know well and strictly comply with the requirements that ensure labor safety. When forging it is necessary:

· Hold the pliers to one side, and clamp the workpiece tightly, for which you should put a safety ring on the pliers (without a ring, only small workpieces can be forged on low-power hammers);

· During the blow of the hammer on the workpiece suspended on the tilter, timely etch (weaken) the chain so that the blow is not transmitted to it;

· All work with a raised hammer woman should be performed only with tongs; do not put your hands in working space hammer without fixing the woman on the stand;

The foreman to give the command to the driver clearly, briefly, in a loud voice;

· The first blow is easy to apply (this is especially true for cases of forging with the use of a backing tool);

· Make sure that the strikers are dry;

Forging only metal heated to forging temperature (it is forbidden to forge "dark" metal that has cooled below 700 0 С);

· When chopping, set the ax strictly vertically; make the last blows on the ax as easy as possible;

· During the cutting, stand away from the end of the cut off workpiece, chop only with a serviceable ax, do not use wedge-shaped overlays;

· Take special care when using backing dies, monitor the centering of the die halves, install the dies strictly under the hammer head.

Conclusion

In the proposed electronic version of the course of lectures "Forging on hammers and presses", free forging operations are considered, for the implementation of which, mainly, a universal working blacksmith tool is used: strikers, axes, stitching, mandrels, etc., and only in some cases when performing upsetting operations , broaching and bending, indicates the application special tool: bottoms, backs, crimps, etc.

However, lately all more forgings are made by forging with the use of special backing dies, which increase the accuracy of forgings, provide less metal consumption, less laboriousness in the manufacture of forgings and greater labor productivity. It is capacious and very interesting stuff, which is a kind of transitional stage between free forging and forging. Studying it requires a lot of time and in this course of lectures this material is not considered. Those wishing to study this material can recommend literary sources:.

On the forging of low-plasticity and non-ferrous metals, which are also not considered in this lecture notes, the following literature can be recommended:.

The skill of a blacksmith of free forging is largely determined by how his workplace is organized, that is, how the equipment is arranged, where the tool, fixtures, blanks, forgings, waste are placed. To achieve high labor productivity, it is important that the distances between the equipment are as short as possible, but at the same time, that all conditions are created for the freedom and safety of movements of all members of the team during forging. There should be nothing superfluous in the workplace that interferes with work.
The blacksmith foreman is the owner of the workplace: he has the right to arrange necessary equipment the way he works best. Of course, it is far from always possible to rearrange the main equipment (hammers, furnaces, presses), and the blacksmith has to adapt, arranging the auxiliary equipment in the right way - racks, tools, containers, etc. In small and medium-sized forges, the restructuring of the workplace can be done by changes in the arrangement of furnaces, which, when overhaul completely disassembled and replaced.
The organization of the workplace when working on a hammer and a press is different and each has its own characteristics.
Let's first look at the most rational ways placement of equipment at workplaces during hammer forging. If the hammer is serviced by a cantilever crane and there is one furnace, then two layout options are possible. In the first of them, the furnace is located in front with the hammer in one line (Fig. 149, a), in the second, at an angle of 90 ° (Fig. 149, b). When arranged in one line, workers working on the hammer are not exposed to heat from the furnace, with the same occupied area, free passage along the line of equipment is maintained, which is especially important in mass production. The crane transferring the blanks from the furnace to the hammer rotates on a semicircle (180° angle). This somewhat lengthens the transmission time, which, of course, is undesirable.

When the furnace is located at an angle to the hammer front, the path made by the crane is shorter (a quarter of a circle), but in this case the team works under the continuous influence of heat radiated through the furnace window, which sharply worsens working conditions and reduces labor productivity. Therefore, if possible, the first method should be preferred, especially if a monorail can be used instead of a jib crane.
Heavy forging hammers are usually served by two furnaces. Possible ways The equipment arrangements in this case are shown in Fig. 150 a and b. If the maintenance is performed by jib cranes, then, taking into account the above considerations, the first method is the best. In the presence of an additional manipulator, such an arrangement can significantly increase labor productivity with a uniform load of all members of the forging team.
In FIG. 151 shows a diagram of the organization of the workplace in the brigade of the Ural blacksmith G. Kovalenko. The work is done with a single swivel crane. The tool, which has to be resorted to relatively rarely, is located in the distance, in a cabinet, the running tool is on the table. The stumps resulting from the forging process are stacked in a box located behind the hammer. Billets and forgings are stacked behind the passage at some distance, but in the area of the rotary crane.

A slightly different layout of the workplace at the Leningrad blacksmith A. Khorkov (Fig. 152). The three-ton hammer is served here by two rotary cranes 3. Near the frame 9 of the hammer, at the level of the lower striker 7, a metal welded table 8 is installed, which facilitates work when tilting the workpiece and reduces the auxiliary time required for this. In addition, heavy fixtures and dies in this case are not removed from the striker, but are shifted onto the table, which also greatly facilitates and shortens the work. The control of rotary cranes is displayed on a separate console (5, 4), standing in front of the hammer at some distance. Fan 6, a place for tools, fixtures, waste, etc. (10, 11, 12) are located near the hammer between the rotary cranes.

The supply of blanks to the heating furnace (1, 2) and the shipment of forgings is carried out by the auxiliary team of the shop. This relieves the main forging team to a greater extent and improves forging productivity.
Another Leningrad blacksmith, S. Pechenko, working on a 0.75-ton hammer, on which mainly small forgings are made, organized his workplace, as shown in Fig. 153. To heat the blanks, there are two furnaces (1, 2) operating on coal fuel. The hammer (4, 9) and furnaces are connected by a monorail. The 3 swivel jib crane allows better use of the oven. Two branches of the narrow-gauge track 5 with a turntable are used to supply fuel and blanks to the furnaces. Tools, fixtures, fan, etc. (6, 7, 8) are located between the ovens.

When working on hydraulic press the layout of the workplace depends on the nature of production and on the type of handling equipment serving the press. Previously, the presses were serviced only by overhead cranes with tilters. Loading and unloading blanks from the furnaces, transferring them to the press, holding them on the weight and all the movements necessary for forging are carried out in this case with the help of a crane and auxiliary devices, and the furnaces must have a retractable hearth. Currently, manipulators are becoming more widespread, providing greater maneuverability, and hence higher labor productivity than cranes. However, when forging very large forgings, overhead cranes with tilters retained their importance.
A typical layout of the workplace when working on a forging press serviced by overhead cranes is shown in Fig. 154. One of the smaller cranes is mainly used for loading and unloading blanks from furnaces and for delivering them to the press. The second available tilter is used for manipulation during forging.

In the presence of a manipulator, depending on its design, several layout options are possible. If the manipulator rail type, then all the equipment can be placed in one line (Fig. 155, a). All movements and movements of the workpiece, including loading and issuing it from the furnace, are performed by the manipulator. If the design of the manipulator provides for the rotation of the trolley, then the press can be located not in a line, but as shown in Fig. 155, b and c. However, this does not provide any special advantages.
The trackless type manipulator gives more freedom in the layout of the equipment, as it has great maneuverability and can go to any place. Such a manipulator provides high-performance operation of the press. If necessary, he can step aside, freeing up the workplace. If, in addition to the manipulator, there is also an overhead crane or a caricature machine that is used to load and unload blanks (or ingots) from furnaces, then the manipulator is busy servicing only the press, and this further increases productivity. Possible variant layout in this case is shown in Fig. 156.

In the manufacture of small and medium-sized forgings, when rolled metal is used as a workpiece, even in conditions of small-scale and single-piece production, it is advisable to organize the work so that the workpieces are cut in the blank department, if any. In this department, it is more profitable to cut rolled products into blanks using special equipment than using hammers and presses in the forging process. In addition, the procurement department supplies blanks to workplaces, prepares the tools necessary for forging and supplies them to workplaces. This unloads the forging team and improves productivity during forging.

As shows years of experience, proper organization workplace in modern production contributes to increased productivity.

The location of equipment, appliances and tools should be thought out, taking into account maximum comfort for work, as well as comply with the safety regulations of each worker, including the blacksmith at the enterprise.

Workplace of a blacksmith in production, they call a site with forging equipment and tooling located on its area. In addition to the main forging equipment, the site is equipped with mechanization tools, heating devices, anvils, vices and tables. The listed equipment is integral part Total technological process blacksmith production.

The workplace of a blacksmith should be provided with good ventilation, lighting, water supply and various protective equipment. Dangerous places must be fenced off with shields, stoves are equipped with hoods. Welding must be carried out in an open area.

The location of devices and devices should not interfere with the movement of the employee, order and cleanliness in the workplace should be maintained. The tools necessary for the work must be located within the range of the blacksmith's working movements.

Tools used right hand, are located on the right, and those that are taken with the left hand - on the left.

No forging industry can do without quality equipment, which includes: forges, coal storage chest, tool boxes, baths for hardening parts.

Very often the quality of the product depends on the equipment on which the blacksmith works.

If you are going to organize your own blacksmithing, in no case do not purchase cheap devices. Better buy equipment domestic production directly from the manufacturer. Thus, you will save money and provide your production with quality devices.

Our company has been producing industrial equipment, and blacksmith including. One of the best domestic products on the market is forge our production. This fact is confirmed by high production and technological indicators.

To care for the forge, you will need a coal shovel, a poker, a pike or a crowbar for punching baked coal, a whisk for cleaning from fine coal and slag dust, a sprinkler for wetting coal when sintering a dome (cap) over the hearth, tongs for coal.

It should be noted that all the tools necessary for forging should be located on a special table in the immediate vicinity of the blacksmith's workplace. Table height 600-800 mm.

In addition to the main and auxiliary tool, the forge always has a box for dry sand, a rack for storing tools, containers for water, a box for coal, racks for storing tools and metal, a workbench for metalworking, etc.

A forge for one is shown in the figure, a. A horn with a fan is set up against the wall opposite the entrance. At a distance of 1.5-2 m from the forge, an anvil is installed, which should be positioned so that its horn is to the left of the blacksmith when he stands with his back to the forge. Enough space is provided around the anvil free space for hammer work. Near the anvil there is a tank with water for cooling the blacksmith's tools and hardening products. The blacksmith's tool is placed on a metal table with two shelves. Top shelf designed for frequently used tools (hammers, chisels, pliers, etc.), the lower one is for less frequently used tools. For the convenience of work, the blacksmith puts the tool on the table so that its handles protrude beyond the edge of the table.

Forge

a - forge for one anvil (1 - fan; 2 - forge; 3 - tool table; 4 - water tank; 5 - anvil; 6 - tool cabinet; 7 - grindstone; 8 - workbench; 9 - blacksmith vice; 10 - box for coal)

b - forge for two anvils (1 - anvil; 2 - table for tools; 3-4 - work tables; 5 - cabinet; 6 - barrel of water; 7 - forge; 8 - hangers for ticks; 9 - grindstone; 10 - pneumatic hammer; 11-hand scissors; 12 - right stove; 13 - chair vise; 14 - rack for blanks)

Spare and rarely used tools are stored in a cabinet. A box for storing coal is installed in the corner near the hearth. They are placed near the wall, on which they produce,. Next set locksmith workbench. AT convenient location store dry sand for backfilling wet places on the floor of the site and rag ends for cleaning tools and other purposes.

The location of the main and auxiliary equipment, as well as a tool in a larger forge is shown in figure, b. A horn for two fires is provided at the far wall. To place ticks on the forge, there are hangers - steel brackets welded to the table. To the left and to the right of the forge, tanks with water with a capacity of 30-40 liters each are placed. At a distance of 1.5-2 m from the forge, two anvils are arranged, and between them there are tables on which the blacksmith's tool is placed. The distance between the anvils is at least 2.6-3 m. The emery sharpener is placed against the wall at a sufficiently large distance from the anvil. Modern blacksmith shops are usually equipped with a small pneumatic hammer with a mass of falling parts of 50, 75 or 100 kg.

Forging stations are often equipped with mobile hand scissors for cutting sheet metal, a regular cast-iron (see) stove measuring 1500X1000 mm, a chair vice, and in some cases also a bench workbench, desktop drilling machine, an assembly table, a rack for blanks, and sometimes a mechanical hacksaw for cutting off dimensional blanks from rolled products. Above the mountain for the removal of smoke and gases are installed exhaust hood. The organization of such forges requires a rather long time and large funds, but such forging sites can be organized simply in the open air or under a small shed.

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