"Mr. Liu, I'm sweating in my palm now. I've never made such a big casting before." Jiang Tao's face was nervous, obviously a little nervous.

Liu Yongzhuo comforted: "Master Jiang, don't you worry. Haven't you calculated it many times? There will be no problem."

Jiang Tao smiled embarrassedly: "Oh, when people get older, they are less courageous. To be honest, have you asked Mr. Liu to review this pouring plan? It must be fine."

"Uh... I'm not particularly good at this." Liu Yongzhuo began to pretend to be modest. The worker in front of him was a hero who followed his father back then, so he dared not show the master's proposition.

Speaking of which, the casting process for this casting that is about to begin is indeed a slap in the brain. Huayang Heavy Industry often has to manufacture some large castings because it produces chemical equipment, but the largest castings in the past weighed more than 100 tons.

This time, what they made was the upper beam of a 15,000-ton hydraulic press. According to Meng Wanlin's suggestion, the entire beam adopts an integrated design, which means that a component weighing more than 300 tons will be directly cast in one go.

The benefits of integrated beam design are very obvious. Since there is no need to use welding or solid nut connection methods, the beam structure will be more stable and can withstand repeated impacts of 15,000 tons of forging pressure.

However, the challenge brought by this design is also very serious, that is, Huayang Heavy Industry must overcome the casting process problem of super-large castings.

The casting process is very simple to say. It is probably to first build a wooden mold that is exactly the same as the casting, and then use special molding sand to bury the wooden mold to fill every gap.

This type of sand must be able to withstand high temperatures of thousands of degrees to the molten steel. It also has sufficient strength to not deform under the impact of the molten steel. After the molten sand is filled, the molder must remove the wooden mold, thus leaving a molding cavity.

During casting, the molten steel is directly injected into the cavity, cooled and solidified, then the molded sand is removed and the casting is ready.

For small castings, this process is not too difficult, but as the castings grow, many problems that are not an obstacle appear.

The first is the so-called "floating core". The casting is not a complete iron mass. Instead, there are various hollows in the middle. These hollows must be filled with sand before casting.

During casting, the molten steel is poured into the sand mold, completely submerging the sand cores at the center of the casting. Since the specific gravity of the molded sand is much smaller than the specific gravity of the molten steel, these molded sands will produce huge buoyancy under the submersion of the molten steel. It is possible to float on the surface of the molten steel from its original position.

Once this core drift occurs, the entire casting process will be considered a failure.

In order to solve this problem, Huayang's stylists thought of countless ways to connect the pieces of sand core with steel bars, and even reinforce them with steel plates to transfer the buoyancy of the molten steel.

Meng Wanlin, An Haoyu, Liu Zhi and other technicians took the computer and calculated it over and over again to ensure that the core was not drifted during pouring.

After overcoming this obstacle, another bigger problem arose, that is, the sand exhaust problem during casting.

Casting is a high-temperature operation. The temperature of molten steel is as high as 1,500 degrees Celsius. At such high temperatures, the molding materials will undergo physical and chemical changes, thereby producing a large amount of gas. If these gases cannot be discharged in time and stay in the cavity, they will form huge pressure and induce an explosion.

It is easy to exhaust the small castings, and it is enough to directly open a few exhaust ports on the sand mold. However, this large casting weighing hundreds of tons has a length, width and height of several meters to more than ten meters. The gas formed is huge in scale. It is difficult for traditional exhaust methods to ensure that all the gas is discharged in a very short time.

In order to design this exhaust system, several engineers from Huayang have been working hard for a month or two, but they cannot come up with a safe and reliable solution.

So, Liu Yongzhuo called on everyone to work together and invite Jiang Tao, an old stylist who had been retired for many years, from home to participate in the research. In the end, it was actually a plan proposed by Jiang Tao that made everyone amazing, that is, to break the previous practice of opening only the exhaust port above the sand shape and adopt the upper and lower exhaust plan.

Once this plan is explained, it will appear very ordinary.

The difficulty of exhausting large castings mainly lies in their excessive volume, but if they exhaust up and down at the same time, it is equivalent to reducing the exhaust distance by half, and the difficulty will naturally be greatly reduced.

Exhaust below is actually very easy, just dig out some exhaust trenches on the ground.

There is another small episode here, that is, after hearing Jiang Tao propose this two-way exhaust plan, Liu Zhi, who holds a doctorate degree from Nanhua University, was depressed for a week. He found that he was in vain to be a senior technician, and in this kind of issue, he was not as rich as an old worker's imagination.

In fact, it is no wonder that the more knowledgeable people are, the more confinement they have in their thoughts, and the easier it is to think about problems based on some rules and regulations. Some old workers who have struggled in practice are very accustomed to taking different strategies and using some methods that are out of the ordinary to solve problems.

Liu Zhi now has a deeper understanding of what Liu Yongzhuo once said to him that he should learn from the workers. What he learned during this psychological setback can be said to be enough to benefit for the rest of his life.

It is easy to propose the idea of ​​two-way exhaust, but how to arrange the exhaust pipes of these two-way exhaust and determine whether the exhaust can ultimately solve the exhaust problem still requires engineers to use scientific methods to calculate.

Liu Zhi used his professional expertise to directly build a large model on the computer, and conducted mathematical simulations of the sand-type gas production, gas production speed, emission speed, etc., and finally came to the conclusion that this plan was foolproof.

In this era, since computer applications are not common enough, large-scale mathematical simulation is still a relatively new subject, and Jiang Tao and others are not proficient in this.

However, as a member of the Liu family, Liu Yongzhuo is very familiar with this technology. He reviewed the entire simulation program made by Liu Zhi, and then went on the machine and rerun it several times. Only then did he feel relieved. The fact that he was able to chat with Jiang Tao so easily at the casting site was also due to his confidence in the entire calculation process.

"Everyone is in place. Start!"

With a call, the oxygen-burning tube accurately faced the eight enclosures on the four enclosures. A series of dazzling sparks flashed, and the enclosures of the enclosures were opened. The enclosures poured down the enclosures and poured into the sand-shaped box.

The sand type sprayed a few meters high blue flame at high temperature, and all the exhaust holes made a whistle-like chirping at almost the same time. White steam gushed out, covering the entire workshop.

Meng Wanlin, An Haoyu, Liu Zhi and others stood in the command position and nervously observed the entire casting process. Liu Zhi held a purchased laptop in his hand, looking at the data on it, muttering words.

Meng Wanlin stared at the surroundings of the box with all his attention, as if he was estimating the exhaust volume with his naked eyes and was ready to issue a command to adjust the pouring speed at any time.

It was just seven minutes, and everyone felt that it was as long as a century had passed.

"Beep!" A whistle sounded, announcing the completion of the entire pouring process. After a brief moment of surprise, the people in the workshop became jubilant together:

"Success!"

“We did it!”

Everyone expressed their inner joy in various ways. The younger workers waved their fists, while the older and more heavy workers shook hands affectionately with their colleagues. Everyone's heart that had been hanging for many days was finally let go.

"Master Jiang, practice shows that the upper and lower exhaust systems you designed are completely effective." Liu Yongzhuo was convinced by Jiang Tao, "Look, the lower exhaust system emits more gas than the upper exhaust system."

"It's all thanks to Mr. Liu's determination. I am an ordinary worker, how dare I take this responsibility?" Jiang Tao's beard shook with joy and replied to Lin Zhenhua.

Liu Yongzhuo was really happy now: "This is the saying goes. If you have an old family, you will have a treasure. This time we cast the beam of the hydraulic press, from designing the exhaust system to sand-burning and shaping, thanks to your guidance from Master Jiang. You old workers are the most precious wealth of our company."

Jiang Tao smiled and said, "Haha, Mr. Lin has been awarded. I have been doing a stylist all my life, and I am dying. It is worth it to be able to cast such a large piece of more than 300 tons in this life."

Liu Yongzhuo did not agree with this. He deliberately looked stern: "Hey, Master Jiang is too pessimistic. In the future, we will still have large castings. Our 15,000-ton hydraulic press is prepared for the forging of large workpieces. At that time, you will be ready to show your skills."

"With this sentence from Mr. Liu, I am young again. Mr. Liu, it's so satisfying to do things with you!"

"Master Jiang, this is not my credit, but you have caught up with a good time. China's industry is about to go global, and some of our industry are likely to do things quickly."

Water-steel pouring is only one stage of the entire beam casting work. After the pouring is completed, the beam needs to be buried in the sand box for a long time to cool until the surface temperature drops to around 300 degrees Celsius, and then the molding cleaning begins.

The cleaning work was extremely difficult. Dozens of workers braved the high temperature and carefully uncovered the cover of the sand box, shoveled the sand with shovels and shovels, revealing the castings hidden inside.

At the beginning, in order to fix the sand core in the middle, the molders used a large number of steel bars. Now, the cleaners had to use an air cutting gun to cut the steel bars one by one, pry them open, and then clean the sand in the middle of the casting.

After half a month of hard work, the sand shape was finally demolished.

The workers drove several large cranes and lifted castings weighing more than 300 tons onto the battery transport truck, then transported them to a specially built heat treatment furnace, and received normalized treatment for up to five days and five nights, so that they met the performance requirements expected by the design.

The further work is to machining the crossbeam. This kind of workpiece of hundreds of tons is much larger and heavier than all machine tools. No machine tool can put down such workpieces.

Of course, there are also solutions to the problem, that is, let the machine tool rotate around the workpiece. At the most stressful time, in several directions of the beam, several machine tools are activated at the same time, boring, tapping, and polishing, which is a scene of an ant gnawing on the bones.

Just a beam made hundreds of people from more than a dozen different types of jobs toss for several months. In addition, there are also a series of work such as laying bases, installing columns, lifting beams, etc., and there is no need to say much about the hardships in the process.

After the installation of various large structural parts, the workers began to install mechanical systems, hydraulic systems and electrical systems. This is equivalent to installing muscles, blood vessels and nerves on the water supply press, allowing it to gain life.

This reflects Huayangzhong's advantage in working as a large equipment manufacturing enterprise. After more than ten years of development, southern China has now possessed a large number of talents in all aspects.

There are hundreds of senior technicians at Huayang Heavy Industry alone. It can be said that no matter which process it is, many large heavy industry enterprises in China can organize a team of workers and technicians who are capable of being elite soldiers.

From the initial project establishment to the beach on the south bank of the Yangtze River, before we knew it, a year passed quietly, and Hua Yang finally ushered in the celebration of the hot load test of the water press.

As early as a year ago, He Yongnian told Liu Yongzhuo that this 15,000-ton hydraulic press is not only Huayang's property, but also the industrial reserve of the entire country.

On the day of the test run, hundreds of people came, including several major committees that manage technology development within the government and representatives of hundreds of domestic equipment companies, which squeezed the entire test run site into a mess.

Liu Yongzhuo and other senior managers of Xinghua Community came to the scene. At this grand celebration, they wanted to accompany every guest who came to congratulate him.

"Mr. Liu Yongzhuo, your Huayang Heavy Industry has done an amazing thing that benefits the country and the people! It can be said that it benefits the present and the future." Naturally, those who speak in high positions are the government officials in high positions.

"General Manager Liu, compared with your 15,000-ton hydraulic press, our hydraulic press will become the old, weak, sick and disabled. How about it, your experience in building a hydraulic press cannot be kept confidential."

This is from the military and Tianyu Group's colleagues. Their eyes were full of jealousy, and they wanted to go back and report to their superiors immediately and ask for the same or even larger water press to build them.

"General Manager Liu, our two companies have always cooperated very well. In the future, if I have any big items to forge, Mr. Liu, please give priority to it." He said this. Then it belongs to companies that do not have a hydraulic press and are looking forward to borrowing Huayang's hydraulic press to make large forgings in the future.

Among all the guests, there are several very special ones, including Professor Dong Ruizeng, a mechanical engineering tutor from South China University.

"It's really outstanding!" Dong Ruizeng turned around the hydraulic press several times. With his professional level, he could naturally see that the hydraulic press is unique in terms of automation level, accuracy, reliability, etc.

He instructed Liu Yongzhuo: "Xiao Liu, the experience you formed during the construction process and the problems you encountered must be sorted out in a complete way and give us a copy. These practical experiences and data are very valuable assets."

"Teacher Dong, don't worry, we have a complete file of all these information. We can provide it at any time when you want it, Teacher Dong." Liu Yongzhuo held the old man's arm and had a friendly attitude. He was originally one of Dong Ruizeng's students.

"Xiao Liu, I'm not wrong with you. When your father founded Huayang Heavy Industry, your company had only a hundred people. He survived by making some iron art for others? In just over a decade, a world-class 15,000-ton hydraulic press actually came from you. It's amazing!"

Dong Ruizeng clapped Liu Yongzhuo's hand and praised, "These are all truths, and the teacher and student are very excited."

"This is also thanks to the talents trained by Teacher Dong." Liu Yongzhuo did not dare to take credit and quickly said modestly, "In our Huayang Heavy Industry, there are the most students who graduated from Nanhua University. In every position, they are all the people who take the lead."

Feng Jiahua, the new general manager of Changsha Heavy Machinery, also came. After taking office, he adopted a policy of close cooperation with Huayang Heavy Industry and sent a group of engineers and technicians including Meng Wanlin to assist Liu Yongzhuo in the construction of the hydraulic press.

So, at this ceremony today, he felt a bit like a hero. After seeing the appearance of the water press, Feng Jiahua chuckled at Liu Yongzhuo: "Mr. Liu, the merits are perfect! I was so jealous when I made such a big play."

Liu Yongzhuo hurriedly handed Dong Ruizeng to the company's secret to take care of him. He took two steps and came to Feng Jiahua. While shaking hands with him, he said: "What did Mr. Feng say? If it were not for your strong support, relying on our Huayang family alone would have to overcome so many technical difficulties."

"No, no, I knew when I was at the Petrochemical Petroleum Corporation that there was nothing difficult in front of you, Liu Yongzhuo." Feng Jiahua was of course not stingy with his praise at this time, and even had the smell of flattery.

"Shame, ashamed. In front of big brothers like Changsha Heavy Machinery, we will always be younger generations."

"A newborn calf is not afraid of a tiger, but a young man is afraid of a young man. We who are big brothers are really behind."

"Mr. Feng, you are polite. If you have any large forgings in the future, you can take them over. As for the processing fee, I will make sure you have a 20% discount."

"Hahahaha, Mr. Liu is so smart. I thought that with our friendship, you can waive us the fee directly. After a long time of trouble, it was only 20% off."

"Well, we have a small capital and low profits, so it's really a difficult situation to waive the fees. Mr. Feng also knows that when the water press is turned on, the electricity and water bills are not a small amount. Also, the daily maintenance cost is not low, so..."

During the laughter and laughter, some preliminary cooperation intentions were finalized, and even the price was negotiated.

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