Contributed to a decrease in demand for transportation services from abroad. In addition, the Government supported the initiative to increase the cost of registration of "constructors", that is, cars imported for individual spare parts. Even in the latter case, the minimum costs will exceed 5,000 euros, not to mention the import of a fully assembled car. There remains one more option that is still available to the Russian consumer - it involves cutting the body into 2-3 parts and importing the vehicle under the guise of scrap metal or spare parts that are not an assembly kit. The scheme is quite simple, and there will be no problems with customs clearance, but there is one more question - how to formalize the cut in a legal way?
Option 1. Frame SUVs
As cuts from Japan, large frame SUVs are most often transported,. The reason for this lies not only in the love of domestic drivers for large cars, but also in the simplicity of design. In Japanese frame technology, there is no body number in principle - the frame number is used instead. Accordingly, the body of such a cut is divided into two parts (the front end with the engine compartment is often cut off) and separated from the frame. Customs clearance for sawing a large SUV is carried out according to two schemes - body halves can be called scrap metal or spare parts in documents - the first option is cheaper, but raises suspicions of the civil service, and the second is more expensive, but legally impeccably clean.
Making a cut will require the presence of a donor car. Previously, a scheme was used with the purchase of a ready-made TCP, but recently the traffic police has required the presentation of a base vehicle, which serves as the basis for conversion. They usually buy burnt, drowned, broken in an accident and causing damage to another type of car, since when making a cut, it makes no sense to overpay for a car that is used only formally. Experts recommend refusing to buy cars and documents, the owners of which:
- Died;
- Convicted under criminal law;
- Have debts to banks;
- Engage in illegal activities;
- Bought a car fraudulently.
Experienced motorists who know the cut are advised to hire a tow truck and go with all the donor hardware to the traffic police department. In addition to the donor for cutting, you need to present a cargo customs declaration for imported units, including the frame, body halves and motor. In some cases, law enforcement officials require you to provide sales contracts that indicate that the car was not received as a result of theft.
The owner of the cut must fill out an application for the replacement of units, the form of which is issued to him by a representative of the traffic police. If the series of the donor and sawn car completely match, the registration procedure ends here, and two weeks later the driver receives the long-awaited documents. If the car models differ, the owner of the cut is sent to NAMI, where they will need to present the finished car that has passed the welding and assembly procedure. At the maintenance point, the cut will be checked according to a special table for the replacement of units developed by the institute. Under normal circumstances, documents for the car will be issued in a week or two, although any problems that arise can stretch the registration procedure for years.
Option 2. Bearing body
If the car is devoid of a frame, making a cut will be much more difficult. The problem is not only assembly, which inevitably loses the strength of the vehicle. According to Russian customs rules, it is impossible to assemble a body from two parts without receiving a separate customs declaration and an agreement for it. Accordingly, when contacting the traffic police, the driver will simply be sent for the missing documents. It is useless to protest, because, unlike, all cars with a monocoque body have a separate plate with numbers, which is the reason for issuing a gas turbine engine.
In this case, the registration of a cut is possible in the only way - the already imported body must be welded and go through the full customs clearance procedure by paying a fee of 5,000 euros. Of course, many people are not willing to pay such a large sum of money, especially when it comes to a Japanese sedan from the 80s. Therefore, motorists are looking for alternative ways to design cuts that do not always comply with the law. We include them specifically to protect readers from liability when using dangerous methods out of ignorance:
- Registration of the body as an emergency with a reduction in duty up to 3500 euros;
- Transferring the plate from the donor to the new body;
- Buying gas turbine engines on the black market;
- Purchase or forgery of documents for the body, confirming that it was imported into Russia several years ago.
Costs and profits
When buying a frame SUV as a saw cut, the result fully justifies the costs incurred - the cost of the car will be 3–10 times lower than that of a similar one that has passed full customs clearance and 10–20 times lower than a new one. But it is not recommended to import frameless vehicles as cuts - there are few cases of legal registration of such vehicles. You should not rely on the offers of various agencies that offer, cheaply and legally - you may face criminal penalties and forcible seizure of the car.
"Constructor"
But let's start with the "constructor" - the first popular way to avoid customs payments. This is the answer of the dodgy representatives of the auto business to the actions of the Russian government, which raises duties.
The scheme for importing a car under documents appeared several years ago and soon became widespread. The idea is simple, like everything ingenious: why pay the full cost of customs clearance of the car, if you can arrange for the replacement of units - the body and the engine. The rest (except for the frame) is not numbered, which means that it does not need registration. Thus, a citizen who had already once paid his native state for the import of a foreign car, got the opportunity to get off with little blood when changing the car to a more recent one of the same model: pay the duty for the import of spare parts, pay a little money for registration. The result was a fresh car with PTS from the previous one and the replacement of units included in the passport. And the old car, which ceased to be legally a vehicle, became a collection of spare parts. "Constructors" were supplied and enjoyed success. Because that was the only way to import a car older than seven years (without the crazy full duty adopted in September 2002).
Everyone rejoiced: both citizens who bought old, well-proven cars for affordable money, and sellers who received earnings.
But all good things come to an end quickly. A year ago, the government of the Russian Federation came up with the idea to close this shop by raising the import duty on the body for cars. Since November 14, 2008, the rate of import customs duty on bodies has become equal to 15 percent of the customs value, but not less than 5,000 euros per 1 piece! Therefore, the "constructor", having risen in price by 5000 euros each, lost its main trump card - an affordable price.
Cut - how is it?
In whose head and when the idea to cut cars arose is unknown. When the Japanese learned about this technology, they were shocked. Yes, everyone is shocked when they find out!
"Sawing" began to appear in the spring of 2009. A causal relationship with the resolution on import duties of January 11, 2009 is visible, in which duties on cars increased significantly and actually made it inexpedient to import cars older than 5 years, with an engine capacity larger than that of a small car.
And, as they say, the hucksters thought of it. In Japan, the back of the car is sawn off at the factory seams along the rear pillars and the threshold. It turns out two parts, they are not legally and physically a car - these are spare parts.
Jeeps are lucky in this regard: they are sawn "slightly", usually only the back, but there is also the option of sawing off the "muzzle"; while the supporting frame remains intact, because for its import you do not need to pay those ill-fated five euros. After import, the car gets to the repairmen, welded, puttied, painted and acquires its original appearance. In terms of its qualities, it is similar to a car after an accident, but not the whole. Most citizens are not embarrassed by this - after all, the frame is untouched.
But models with a load-bearing body - both SUVs and cars get there - after restoration in garage conditions, they become a machine only externally. The car cannot acquire its properties: the rigidity and strength of the body, which were laid down by the manufacturer, are violated. When it gets into an accident or after a set of high speeds, it falls apart - handicraft welds burst. Those who were sitting in the car die.
Price and legality
But the unreliability of the car is one side of the coin. There is also a second one. There is an order of the Ministry of Internal Affairs, according to which, when replacing units, a copy of the customs declaration for the body must be presented (since this is a numbered unit). When cutting, there will be no such document, which does not allow this machine to be registered legally.
It is possible to issue a "sawing" only by welding a panel carrying the body number from the old car during assembly into a freshly brought body or by forging a gas turbine engine on the body. This is fraud and fraud. Meanwhile, in Vladivostok, there are firms that openly offer to bring "sawing" and ask the client: is there an old "hardware" (apparently, so that there is where to get the body number)? To questions about the quality of such a "home" assembly, the sellers answer: "The cut is made at the factory seams. After normal welding, the car will not lose its characteristics, nothing will fall off or burst. We can bring the sawn car, clear customs and give it to you as it is, without assembly .If you have doubts about the quality of our welding, you can assemble the machine yourself."
Well, thank you - not every house has at least a soldering iron!
The cost of "sawing" without import duties is more attractive than the price of the car after all payments.
I will give a method for calculating the cost, which is used by the firm-seller. "In order to determine how much a "designer-sawing" will cost, you need to determine the average cost of such a car at auctions. Next, we add expenses to the cost of a car:
85,000 yen The cost of services in Japan, including the auction fee, transportation of a car to the port of departure from the auction, registration of export documents.
650 USD Cutting frame jeep, minivan, bus in Toyama. If a car is cut, then 600 dollars.
600 dollars Sea freight from Toyama to Vladivostok.
500 to 1,500 USD Customs duty, it depends on the weight of the car. For example, the weight of the Toyota Land Cruiser and Suzuki Escudo is completely different: the duty on the Escudo is $700, on the Cruiser it is $1300.
RUB 26,000 Customs temporary storage warehouse and services of a customs broker for customs clearance.
$1,000 Car collection, including removal by truck crane from the port, welding-painting-installation of units, filling liquids.
How to calculate "sawing"
However, it is not easy to calculate the sawn machine. The head of the technical supervision department, Nikolai Barkhutov, explained that if the vehicle came for registration with the traffic police with a title already issued to the owner, and the body and engine numbers matched those indicated in the passport, then there is no reason to refuse registration. So far, thank God, in Buryatia there have been no cases of accidents involving saw-cutting cars, as in other regions.
But in the Ulan-Ude car market there are "cuts", and quite a few. This is reluctant and only secretly confess sellers. I was shown a couple of Toyotas confidentially. Outwardly normal cars, without visible traces of body repair, with a large engine: it is unprofitable to cut and cook a small car.
The cutting machine must be impregnable. And the seller will say that this is an ordinary "constructor". The places of cutting and welding will come out only in case of an accident, when it will be too late. Crawl through the skin to see the place of the proposed weld, not a single seller will allow. Therefore, it is advised to look at the TCP and by the body numbers through the auction "punch" when the car was bought in Japan. If after the new year the car is also declared as a "designer" - this is a "sawing".
A familiar bodybuilder advised me to look at the places where the body was cut; for SUVs and SUVs, these are the luggage compartment windows. You can see traces of welding there. Armed with this information, I went along Prirechka and found a couple of suspicious cars myself.
Familiar distillers advised to pay attention to Harrier and LC Prado.
My friends asked me not to say the word "sawing" even in a whisper - otherwise they would "roll into asphalt."
Having gone through all the Toyota jeeps and SUVs that do not have local mileage, I finally found two Harriers with clumsy seals on the "windows". Both without mileage, with maximum three-liter engines and over 5 years old. Both cost together more than a million - with this money you can "roll asphalt" very thickly! I could not even believe that here it is, this horror!
I stared silently and went on, thinking about my own. For example, the fact that the public that buys expensive cars treats them without trepidation is not the first and not the last car. "Japanese" have long won the reputation of being reliable, and it is unlikely that a reputable buyer will climb the body, examining every centimeter personally, as poor motorists do. And in vain, as it turns out!
P.S.*If this material prevents at least one accident and saves someone's life, I will be happy. And don't give thanks.
*No one would invent these dangerous schemes if the state did not remove the opportunity to import a used foreign car into the country at normal duties. Here is a dialogue from one Internet forum (style saved):
“I came up with the idea: when bread is baked, there are also crumbs left to the dick. Take them for a penny, glue them into bread molds and sell them.
"That's when bread rises in price and becomes a luxury, then craftsmen will appear who will glue the crumbs. God forbid we live to see such times!"
On the territory of the Russian Federation, under the full duty, it is allowed to import cars of 2007 and younger. Cars older than 2007 can only be brought in for dismantling (without PTS): sawing, constructor or carpiling (sawn off TV and partial disassembly of the interior).
It is forbidden by the law of the Russian Federation to legally move on public roads on cars imported to the territory of the Russian Federation in the form of spare parts (cuts, carpiles, designers). The Sferacar company does not deal with the design of constructors, does not produce documents for movement, does not weld strips, etc. Our company delivers cars to the Russian Federation, clears them in the form of spare parts, assembles a saw cut, carpil or constructor (at the request of the client) and transports them to any city in the Russian Federation . We do not know about all further actions of the Client with this car (assembled from spare parts) and do not give advice regarding movement.
Cuts
Cars imported by cut from Japan are the only option for restoring a car after a serious accident or updating your dilapidated car with spare parts taken from a cut. At auctions in Japan, you can easily find cars aged 20 years or more with a mileage of 20,000 km or even less! If you are a fan of the Japanese car industry of the 80s, 90s and early 2000s, then the cut will completely update your car with high-quality chassis parts, internal combustion engines, transmission, body parts, interior parts, etc.
Thousands of cars are sold at auctions. You can easily find a car in a rare color, configuration, with the right transmission, the desired mileage and technical condition.
The cuts are sawn into two parts so as not to pay a fee for the "body" (2,900 €). Sawing is possible both on the front and on the back (the floor and roof pillars are sawn).
After customs clearance, CCD documents (cargo customs declaration) are issued:
- For passenger sawing: gas turbine engine for the engine;
- For a frame jeep: gas turbine engine for the engine and gas turbine engine for the frame;
- On a truck: gas turbine engine for the engine and gas turbine engine for the cab (if the truck was delivered by cut)
Scheme of cutting a car
A passenger car can be sawn along the back (rear pillars and along the floor) and along the front (pillars and along the floor).
Cut on the back:
Buses are sawn only on the front, the engine remains in place.
Scheme of cutting a frame car.
Cars with a frame (jeeps) can be sawn both in front and in the back. The engine and chassis remain on the frame. The body is removed from the pillows, the electrics, brake and fuel pipes are disconnected. If you don't need a frame, we can cut it, so you don't have to pay the frame duty.
We disassemble the car in specially equipped boxes, where the car is first prepared before cutting: the interior plastic is removed at the cut point, the wires, pipes and hoses of the fuel and brake systems are disconnected, the muffler, cardan and all other parts that are or pass at the cut point are removed car. All dismantled elements are packed in a film, and neatly folded into the interior and trunk of the car. After cutting, the car is closed on the rear or front doors, and in the places of cutting, the body is pulled together with metal plates on self-tapping screws. This saves the car from "collapse" into two parts. The cut arrives in the port of Vladivostok in this form, so that rainwater, dust and dirt do not get into the car. In addition, this solution protects the removed parts from theft by unscrupulous port storekeepers.
A new type of car cutting is also used: the trunk is sawn off along the rear fenders. The floor and pillars of the car remain intact! The car retains the ability to move, independently drives into the car transporter and is able to cover short distances.
This type of car cutting is suitable for those who want to update their car with fresh spare parts, make a “swap” (instead of an atmospheric engine, a turbine engine, computer, scythe are installed), or want to repair damage to the rear of the car after an accident. Note that this type of car transportation is cheaper than the classic car cut!
Assembly of cuts
The cuts are assembled by professionals with 9 years of experience! High-quality welding of cut places, at the request of the client, metal duplications can be welded to increase rigidity. Also, at your request, you can “hide the seams”, this procedure will allow you to hide the traces of the saw cut even when inspecting the car in the pit.
To find out the price for bringing a car by cut, use or contact.
Constructors (whole body)
It is possible to import a car by a designer. From March 24, 2018, the duty on the whole body has been reduced from 2,900 € to 15% of the cost of the car.
Our constructor video:
The car is delivered by a designer from Japan in the following form: the internal combustion engine and wheels are removed. The rest of the car remains in place. After customs clearance, two CCDs (cargo customs declaration) are issued to the designer:
- CCD for the car body indicating the model and body number;
- The second GTE contains the engine model and number.
- If the car is frame, then three gas turbine engines (body, frame, engine).
If you need to assemble a designer car, our specialists will professionally assemble your car!
This type of import is suitable for those who want an unsawn car:, etc. For an accurate calculation, go to or contact ours!
To find out the price for bringing a car by a designer, use or contact.
Karpils
AT THE MOMENT THIS METHOD OF IMPORT IS PROHIBITED BY THE CUSTOMS OF THE RUSSIAN FEDERATION!
Cars imported by Karpil from Japan are an excellent option for restoring a car after an accident or fire. When importing a car by carpil, the whole roof racks and the floor of the car remain, thus this type of import will be of interest to Clients who want to move in the future by carpil. The cost of importing a car with carpiles is slightly higher than importing a car with a cut from Japan.
The method of importing a disassembled car: the front optics and bumper, front fenders, tubes, pipes, wires were dismantled, and the “TV” was sawn off to the engine mount.
This method of importing a car is beneficial for those that the car body itself remains intact (except for the TV).
We carry out the assembly of carpiles / frames / body shells. All work on the assembly of designers is carried out by high-class specialists, thanks to which we can guarantee the absence of technical problems with both the electronics and the mechanical part of your car. The photo, as an example, shows how some parts of the car are attached to the pallet, and carpiled during the assembly process.
To find out the price for bringing a car with a carpil, use or contact.
Trucks for analysis (for documents, TCP)
Upgrade your dilapidated truck with quality truck parts from Japan!
Truck repair in Russia is very expensive. Contract engines and gearboxes (for which the real mileage is not known) are expensive, and if the cab or frame has begun to rot and corrode, then contract spare parts and repairs will not help here. The most expedient option for restoring your truck is to bring the truck by a designer from an auction in Japan! It is possible to assemble / transfer already to your frame on our truck assembly.
Trucks can be imported into the Russian Federation in disassembly, while not a single part of the car is sawn! The cab, headlights are removed, the engine remains in place.
An example of a disassembled designer truck:
If you decide to purchase a construction truck from a Japanese auction, then you will be presented with a wide selection of all possible chassis options: flatbed, refrigerators, booths, isothermal vans, awning, with a manipulator, motor home, dump trucks, waste trucks (with a barrel), concrete pumps and many others. Various options for technical condition, mileage, year of manufacture, drive.
The truck can be brought cut (option for spare parts). To do this, the installation is removed from the frame (board, booth, etc.), and the frame itself is sawn behind the cab, the rear axle with wheels is fixed with steel wire to the rest of the frame. The meaning of this principle of importation is to save on transportation by ship, and a slightly lower cost of duty, due to the fact that the sawn frame will not be subject to duty. Truck cuts are a good solution when only an engine, cab, gearbox, running gear is required.
22.05.2015Purpose and types of frame saws
Frame saws - the cutting tool of sawmill one-two-story and container vertical sawmill frames. They are designed for longitudinal sawing of logs into beams, bars, boards and a container plank. Tool factories currently produce two types of saws: for vertical sawmills according to GOST 5524-62 and for container sawmills according to GOST 10482-63.
Frame saws according to GOST 5524-62 are made in two types (Fig. 29, a): type A (I) and type B (II). Type A saws have riveted bars at the ends, but B saws do not. Gang saws of type A are fixed in saw frames with removable grips and are used in saw frames with continuous feed. In these frames, depending on the amount of log feed, a change in the slope of the saws is required, and the design of frame saws with slats allows the necessary change. Type B saws are mounted in the saw frame with riveted grips and are mainly used in sawmill frames with a log inching feed per working stroke, in which a change in slope is not required. Te and other saws can be operated with set flattened teeth.
Saws for container sawmill frames are produced without straps according to the drawing in fig. 29, a. They differ from the sections considered at the ends of the blade, which are free from teeth (40-60 and 70 mm, respectively) and the dimensions of the blade itself. Such saws are also installed in the saw frame with the help of riveted grips.
The productivity, cut quality and durability of frame saws depend mainly on their design and preparation for work.
Gang saw design
The frame saw has two main elements; canvas and a gear rim notched on one of its edges.
The saw blade is characterized by its dimensions: length L, width B and thickness s (Fig. 29, a). The length of the gang saws depends on the stroke height of the saw frame and the maximum diameter of the sawn log and can be determined from the following relationship:
To increase the rigidity of the blade in the transverse direction, saws with the shortest possible length should be used. Saw blades for vertical sawmill frames are available in three widths: 160, 180, 200 mm, and for tare frames - 80 mm. As the teeth are sharpened, the width of the blade decreases. The minimum blade width that provides sufficient strength and rigidity for saw blades in operation is approximately 75 mm. The thickness of gang saws is determined by a number of conflicting requirements. To increase the rigidity (stability) of the saw during the cutting process, it is necessary to increase the thickness. An increase in thickness leads to an increase in the consumption of wood into sawdust and cutting power. The thickness of the frame saws is approximately determined by the empirical formula:
A smaller value of the coefficient (0.1) is taken when sawing softwood with flattened saws, a larger value (0.12) - when sawing hardwood and frozen wood. When sawing logs of significant diameters, the middle saws in the set are set 0.2-0.3 mm thicker than the outer ones. The dimensions of frame saws manufactured by domestic tool factories are given in Table. 14.
Gear ring design frame saw is shown in fig. 29, b. GOST provides for the production of all types of frame saws with a tooth profile having a broken back edge.
The following values of the linear and geometrical parameters of the tooth have been established by the practice of work. Tooth pitch (according to TsNIVMOD)
For a flattened tooth, an increase in pitch is allowed due to the better quality of the sawn surfaces. The choice of tooth pitch should be made depending on the working conditions and the thickness of the saw (see Table 5).
The height of the tooth is set from empirical dependencies:
The higher the tooth, the lower its rigidity, but the greater the volume of the chip cavity. Therefore, when the cavity is not stressed, a smaller tooth height should be taken. To improve the conditions for the movement of chips in the cavity, its bottom is formed along the radius r, the value of which is determined by the following empirical dependence:
The volume of the cavity is better used with a smaller pitch of the teeth, but their higher height. A larger radius of curvature reduces the resistance to chip placement in the cavity. The dimensions of the teeth of the frame saws are given in Table. 15.
Saws according to GOST have a symbol. For example, when applying for saws for vertical sawmills of type A, 1600 mm long, 180 mm wide, 2.2 mm thick, with a tooth pitch of 26 mm, they are designated: PR-A 1600x180x2.2x26, GOST 5524-62.
For container saws, in the symbol, instead of PR, PTR is put and the type and width of the saw are not indicated.
Technical requirements for accuracy and quality of gang saws
Frame saws are made of steel grades 9HF in accordance with GOST 5950-63 or cold-rolled band of steel 65HF. The hardness of saws along the entire length should be within HRC 42-46, and for container saws with a pitch of 15 mm HRC 45-50. Limit deviations of frame saws from the established dimensions should not exceed the values \u200b\u200bspecified in Table. 16.
Design options for frame saws
In sawmilling, frame saws of several design options are used.
Cross cut saws(Fig. 29, b) can cut off groups of fibers (whiskers) formed on the lower face of the sawn timber and connected to it by one of the ends. The pitch of the undercut teeth is 16 mm, they are cut in such a way that in the upper dead position the lower undercut tooth enters the cut by 10-12 mm, the divorce is 0.1-0.2 mm more than that adopted for the cutting teeth of the saw.
Planer saws(Fig. 29, d) are used for simultaneous planing of sawn products with high humidity with low requirements for surface cleanliness (bridge building and shipbuilding beams). The disadvantage of such saws is a relatively short service life due to the presence of slots for planing cutters.
Saws with teeth equipped with tungsten carbide blades, the most efficient type of cutting tool. However, the creation of reliable workable saws of this kind requires extensive production experimentation.
Preparing frame saws for work
Preparation includes attaching planks or grips to the ends of the saw, straightening and rolling.
Fastening bars and grips to the ends of the saw. To install saws of type A in the saw frame, it is necessary to rivet two strips to the upper and lower ends of the saw. The bottom end of the straps are riveted at the factory. A set of strips and rivets for the upper end is sent by the factory together with the saw, and their fastening is carried out at the place of operation. Before riveting the strips, the saw is cut in length if it does not match the length of the saw frame, and in width if there are broken teeth, cracks or a discrepancy between the tooth pitch and sawing conditions. Trimming is carried out at a right angle to the trailing edge on the PSh-3M, PShP-2 sawmills or scissors. Marking is done using a ruler and a square or a template ruler, the length of which is equal to the distance between the saw blades. Holes for rivets are punched with a beard and a hammer or on a saw die with a round punch along the markings or the jig. Hole diameters should be 0.5 mm larger than the rivet diameter, and the accuracy of the distances between the hole axes is ±0.1 mm. After riveting the strips on one rivet, checking the supporting surface of the strips along the square and matching the holes in them with the holes in the saw, a second rivet is placed, etc. The heads of the rivets are ground flush with the surface of the strips. Similarly, grippers for type B saws and tare saws are riveted.
Editing of saw blades. In the process of manufacturing and operation, due to uneven tension, strong heating, transverse bends of the frame saw blades, local defects are obtained: bulges, tight spots, weak spots and transverse bends (Fig. 30, a). These defects disrupt the normal operation of the saw, therefore, before rolling, they are corrected manually on the anvil with special saw hammers (Fig. 30, b). To detect defects, the saw is bent in a special device with a radius of curvature of about 2 m, and both of its surfaces are examined in turn with a short test ruler (see Fig. 27, i). When determining the exact boundaries of defects, the ruler should be rotated at different angles to the longitudinal axis of the saw. The boundaries of defects are outlined with chalk.
Bulge B (see Fig. 30. a) is found in the form of a bulge on the inside of the curved saw and a depression in the same place on the other side. The bulges are removed with a saw hammer with a round head. The first light blows are applied around the bulge, then along its edges. Finish editing with stronger blows to the center of the bulge. In order to avoid stretching of the metal between the sheet and the anvil, several thick sheets of paper are laid or editing is performed at the end of the hard rock churak. Bulges of an elongated shape are straightened with a hammer with an elongated striker. Blows are applied from the edges of the bulge along the length to its middle. After correcting on one side, the saw is turned over and ruled in the same way on the other side.
Tight place T is found as a bulge (hump) on the inside of the curved saw in any of its positions. The tight place is eliminated by double-sided forging or rolling with elongation (stretching) of the metal. When forging, the saw is placed on the anvil with its hump up.
Weak spot C is found in the form of a concavity (light gap) on the inside of the curved saw in any of its positions. The metal in the slack area is excessively elongated and, as it were, surrounded along the contour by the rigid parts of the canvas. In a horizontal position, the slack appears as a bulge. Weaknesses are corrected by double-sided forging or rolling near their edges to stretch the metal near the weak point.
Bending And is found in the form of a curvature of the canvas, most often at its ends. To eliminate this defect, the saw is placed on a test plate and a twisting ridge is found, which looks like a bulge. Then the ridges are forged along the axis on both sides with a hammer with a longitudinal striker. The straightened saw should be flat along its entire length and, when applied to the test plate, fit snugly against it with its entire surface.
Rolling of frame saws. The necessary stability, rigidity of the frame saw blade, characterized by the amount of deflection in the lateral direction from the action of the transverse force, is achieved by tensioning the saw in the longitudinal direction. The magnitude of the total tension force is limited by the strength of the saw frame and grips. Usually, the stresses of the edges of the web are increased by weakening its middle part. To do this, the saw is subjected to special processing - rolling. The middle part of the saw blade is rolled between rotating rollers under pressure, as a result of which it is somewhat elongated compared to the edges and receives compressive stresses. If now such a blade is stretched in a saw frame, the side edges of the saw will receive greater stresses and greater rigidity than with an untreated blade with the same tension force. The rigidity of the treated fabric (according to Prof. A.E. Grube) increases by 10-20% compared to the untreated one. Frame saw blades are rolled on special rolling machines PV2, PV5. The hydrokinematic diagram of the PV5 rolling machine is shown in fig. 31, a. Both rollers (3 and 4) of the machine are driven, there is a hydraulic clamp, the pressure between the rollers is set according to the pressure gauge. Rolling speed 10 m/min, machine productivity 150 saws per shift.
The middle part of the saw is subjected to rolling at a distance of 20-25 mm from the trailing edge and the line of tooth cavities (Fig. 31.6). First, the middle band of the saw is rolled, and then symmetrically adjacent sections with a gradual decrease in pressure. The edges of the saw and its ends with a length of 120-150 mm are not rolled. The degree of rolling of the saw is determined by the value of the light gap of its transverse curvature during longitudinal bending with a radius of curvature of 2 m. The transverse deflection is changed with a short test ruler and probes or a test ruler with an indicator (Fig. 31, c). The pressure of the rollers and the recommended degree of rolling, depending on the thickness of the saw, are given in Table. 17 (according to V.F. Fokin).
As the saw wears out, it is rerolled. During the service life, the number of repeated rolling of the saw does not exceed three or four.
Installing, fixing and aligning the saws in the saw frame
The correct position and fastening of the saws in the saw frame is one of the main conditions for the productive work of the saw frame.
Fastening saws in the longitudinal direction. It is carried out by captures of two types: deaf and removable. Blind grips are riveted to the saw blade and are used only for type B frame saws and container saws. Their disadvantages include: the impossibility of changing the slope of the saws depending on the feed rate, bulkiness, the need for riveting as the saw wears out in width, etc. For type A saws, quick-detachable hinge grips with a screw or eccentric tensioner are used. Removable grips (lower and upper) differ from deaf removable grips by the presence of cheeks, with the help of which the saw blades are fastened and tensioned in the longitudinal direction by the strips riveted to the ends of the saw.
The design of screw grips is shown in fig. 32, a. The saws are tensioned evenly and smoothly by turning the M16 screw with a wrench. The disadvantage of these grips is the slow tension of the saws and the rapid wear of the thread, as well as the impossibility of sawing boards thinner than 25 mm.
Eccentric grips are shown in fig. 32b. They are more perfect and therefore the most common. The saw blades are pretensioned by moving the sub-eccentric wedges, and the main tension is performed by turning the eccentric. The eccentric is made with an eccentricity of 5-7 mm along the Archimedean spiral. The wedge of the eccentric grip to ensure self-braking should have an angle of no more than 6-7 °. The eccentric is turned with a special key with a handle no more than 500 mm in order to avoid excessive tension of the saws. Eccentric tensioners provide fast, smooth and reliable saw tension. The dimensions of the main structural elements of the unified grippers ZU-18 and ZU-22 are determined by the strength requirements. The saws should be pulled gradually, in two or three steps, and symmetrically, starting from the extreme saws and ending with the middle ones. The normal rigidity of the saw is ensured in the presence of stresses in its cross section of the order of 8-12 kgf / mm2.
The tension force of one frame saw for two-story sawmill frames can be determined from Table. 18 (according to the norms D98-10 of the Severny Kommunar plant).
In the process of work, the saws, heating up, lengthen, as a result of which the normal stresses decrease and this can lead to poor sawing. The normal heating temperature of the saws is on average 40-50 ° C; the rear edge of the saw heats up by 15-20 ° C higher than the cutting edge. Therefore, after sawing the first two or three logs, it is necessary to additionally tighten the saws. The tension of the saw when it is cooled reaches an average of 14-16 kgf / mm2, which leads to significant deformations of the saw frame and even its breakage. During long breaks in work, the tension of the saws should be loosened.
The listed designs of tension devices have a number of common disadvantages. There is no tension control, and individual saw blades have different tension forces; there is no compensation for elongation of the saws when they are heated; a change in the tension of one saw set leads to a weakening or an increase in the stress state of the others. To eliminate these shortcomings, domestic enterprises use hydraulic tensioners (Fig. 32, c), which make it possible to ensure the same tension of all saws and automatically tighten them when heated. Hydraulic tensioners of the following brands are produced: PG-30 - for a set with a width of 300 m, PG-40 - for a set with a width of 400 mm and PG-56 - for a set with a width of 560 mm. The weight of hydraulic tensioners is 13-22 kg, the tension force is 3000-4500 kgf.
The hydraulic tensioner is a closed non-motorized hydraulic system consisting of three units: a pressure generator, a hydro generator housing, in which vertically arranged pistons serve to support the upper grippers of frame saws, and a support wall. The device is mounted on the upper traverse of the saw frame and attached to it with hooks.
The use of a hydraulic tensioner increases the productivity of sawmill frames by 3-4% due to the elimination of downtime caused by pulling up the saws during sawing, improves the quality of sawing, facilitates the work of the framer and sawmill.
Fastening saws in the transverse direction. It is carried out with the help of special gaskets (separation) and clamps. To do this, the gaskets are inserted between the saws at the top and bottom and compressed with clamps mounted on the racks of the saw frame. Setting the center of the setting in the center of the saw frame is carried out by selecting the side paired spacers placed between the clamps and the edge saws of the setting. To determine the size of the side gaskets, use the template box for the set of set.
Gaskets perform several functions: with their help, saws are fixed in the transverse direction; they reduce the free length of the saws, which becomes equal to the distance between the upper and lower spacers, thereby increasing their rigidity; provide the required distance between the saws. Gaskets are wooden, metal and combined. The most widespread are wooden gaskets (Fig. 32, d). They are light, simple, cheap and cut from dry birch or larch. The disadvantage of wooden spacers is low strength. The thickness of the spacers depends on the thickness of the boards being cut, the shrinkage allowance and the widening of the saw teeth:
Clamps that tighten the set in the transverse direction are divided into clamping and expansion clamps. The most common spacer clamps with one or two pressure bolts (Fig. 32, e). Single-bolt clamps allow for faster set-up adjustments, but make it difficult to straighten the saws parallel to the rails. Clamps mounted on the left stand of the saw frame (along the log) are called root, on the right - clamping. The root clamps are fixed motionless, and the gaskets are pressed by pressing. The lower clamps are set along the height of the saw frame so that in the upper dead position there is a gap of 50-70 mm between the spacers and the line tangent to the upper points of the lower sending rollers. The top clamps are set depending on the maximum diameter of the log in such a way that in the lower position of the frame there is a gap of 80-100 mm between the top spacers and the highest point of the butt of the log.
Alignment of saws in a saw frame. Includes setting the slope, checking the parallelism of the saws to the direction of movement of the log and the line of movement of the saw frame. The slope of the saws is set using inclinometers of the Vardashko system or TsNILSevzaples. These inclinometers have levels with a scale. When checking the slope, the inclinometer is pressed tightly with the base surface to the tops of the saw teeth. If the actual slope corresponds to the required one, the level bubble will be located in the center of the scale; if the bubble deviates from the center, it is given the desired position by hammer blows on one of the ends of the saw. The slope value is set by moving apart the hinged wooden bars (on the Vardashko inclinometer) or raising the level bar with a micrometer screw (on the TsNIILSevzaples inclinometer). The slope of the saws is necessary when the log is fed over idle. It ensures the movement of the line of the tops of the teeth in a horizontal plane and eliminates the pressing of the log on the saws.
The parallelism of the saws is checked using a control ruler and a square (Fig. 32, e). To do this, the control ruler is installed on special squares of the frame of the sawmill frame and a square is applied to it. The long plate of the square, normal to the ruler, will then be located strictly parallel to the direction of movement of the log. On this plate, when moving the square along the set, all saws are installed, first in the upper position of the saw frame, then in the lower position. The vertical position of the saws is checked with the same square. In the upper position of the saw frame, the square is pressed against one of the saws and its position is fixed. Move the saw frame to the lower position. Set the square to its original position and check if its bar touches the surface of the saw. In the case of a gap, the saw blades are moved in the desired direction with the help of upper clamps.
When installing saws in a saw frame, it is necessary to pay attention to the location of the grips along their width, since it has a great influence on the distribution of stresses over the cross section of the saw. Due to the fact that the rigidity of the blade mainly depends on the stresses in the cutting edge, the saw should be positioned in the grips so that the axis of symmetry along the width of the grips, (tension line) is located between the cutting edge to the center line of the saw. The value of the displacement of the tension line from the axis of the saw towards the cutting edge (eccentricity) is recommended (according to Prof. A.E. Grube) 0.15, where B is the width of the saw.
