Heavy-Gauge Sheet Metal Fabrication: Custom Thick Plate Steel Service

Heavy-gauge sheet metal fabrication is a fundamental support system in the mining, heavy machinery, and marine engineering industries. However, high precision machining has always been the industry's biggest headache.

A lot of contract manufacturers still end up producing parts that are easily cracked, which in turn leads to skyrocketing costs. This is mostly due to lack of equipment or the proper control of internal stress.

This article will analyze the rationale behind heavy metal processing by first discussing, among others, how to pick the right material, which bending methods should be used for large scale metal forming, and how LS Manufacturing can provide fully tailored solutions from start to finish.

You will get a profound insight into the nature of large scale metal production from this article. Most importantly, it will help you keep your heavy metal projects durable even under the most demanding conditions - which is basically professional sheet metal fabrication in a nutshell.

Heavy-Gauge Sheet Metal Fabrication: A Quick Overview Of Key Solutions

This article gives a quick understanding of the main problems and solutions in heavy plate processing. Hiring expert sheet metal fabrication services is one way to help you stay clear of processing hazards, cut down on expenses, and do more work in less time. More explanatory information on each remedy will follow shortly.

Why Trust LS Manufacturing For Heavy-Gauge Sheet Metal Fabrication? Expertise In Custom Heavy-Gauge Fabrication

When you choose LS Manufacturing as your heavy-gauge sheet metal fabrication partner, you are choosing a company that can turn technological advantages into real benefits for customers rather than just throwing out equipment specs one after the other.

We control raw materials based on ASTM A6/A6M-21 steel plate standards, thus, each plate is checked for tensile strength. Besides, we comply with AWS D1.1-2020 steel structure welding specification requirements strictly which is a assurance of the quality of our processing from the supply source.

We offer competitive quotes to clients by figuring out the direct material sourcing from the steel mills and using the best nesting software for material utilization.

Our own production lines enable us to do away with third party suppliers thus we have raised our delivery efficiency by more than 40% and also we have eliminated the risk of damages and delays during transit.

Our advanced methods such as spectral analysis and laser tracking detection can be of great help to our high end customers who are struggling with cracking and deformation problems of thick plates.

Our capabilities are well supported by actual international cases, such as the 45mm vibrating screen side plates which were customized for a mine in Australia and their service life was increased from 2000 hrs to 6500 hrs plus.

If you are struggling with high precision sheet metal fabrication services, feel free to contact our engineers for a free process feasibility analysis and unlock a customized solution to make your project more cost effective and stable.

Figure 1:​ Operator bending thick steel plate on heavy-duty industrial equipment.

Why Is Yield Strength Key In Heavy-Gauge Sheet Metal Fabrication?

In heavy-gauge sheet metal fabrication , the material yield strength is the main factor that affects processing safety and product lifespan. In fact, selecting the right material may totally exclude the risk of brittle fracture. Besides, a material is generally matched to a particular use scenario.

Main Choices of Material According to Different Application Environments

1. Mining and Heavy Machinery: High strength steel plate of ASTM A572 Grade 50 (tensile strength of 450-550MPa) is the type of steel intended in this case, which can keep up with high frequency vibration and impact, thus preventing component failure prematurely.
2. Typical Load Bearing Structures: ASTM A36 carbon steel (having a tensile strength in excess of 360MPa) is the one that is picked, giving a fair price and satisfying the requirements of thick plate processing in the usual style.
3. Wear Resistant Uses: The high strength wear resistant steel plates which include the HARDOX series must be chosen because these plates which have a hardness greater than 400HB serve as protective material for components that undergo everyday operational wear in vibrating screens and crushers.

Main Tips for Quality Inspection of Raw Materials

The high carbon equivalent results in cold cracking during the welding of thick plates. We shall carry out the spectral analysis and hardness testing at the receipt of raw material for the plates' thicknesses over 25mm in order to ensure their tensile strength, thus making the risk of brittle fracture to become as low as possible starting with the source.

Figure 2:​ Material strength comparison chart: yield vs. fatigue.

How To Control Deformation In Industrial Thick Steel Sheet Fabrication​ With Laser Cutting?

In industrial thick steel sheet fabrication, thermal cutting physical deformation is a common pain point, and the hardening of the heat affected zone can cause uneven edges of the thick plate, requiring secondary precision grinding. We found the optimal solution through process comparison.

Comparison of Core Parameters for Different Cutting Processes

Core Process Optimization for Thermal Deformation Control

The application of water cooled circulating cutting technology enables us to achieve a 15% reduction in thermal deformation for heavy industrial thick steel sheet fabrication processes. The cutting process produces edges with high smoothness which require no additional processing for welding. This method decreases both labor expenses and time requirements.

How To Achieve Precision Angle Control In Heavy-Gauge Metal Forming Service?

Heavy-gauge metal forming services encounter their primary difficulty with maintaining control over springback movements. The process of bending thick plates creates angular deviations which become more pronounced when working with plates that exceed 50mm thickness.

The assembly process encounters severe problems when the deviation reaches excessive levels which require accurate compensation methods to resolve.

High Precision Angle Compensation Equipment and Technology Support

The 1200-ton CNC bending machine which we possess includes a dynamic mechanical compensation system that enables us to monitor springback data in real time while we perform automatic angle adjustments and maintain precise control over springback capacity which results in accurate forming.

Reference Bending Parameters for Different Plate Thicknesses

The reference bending parameters for different plate thicknesses are as follows:

What Welding Process Ensures Quality In Custom Heavy-Gauge Steel Parts?

The core load bearing structures will use custom heavy-gauge steel parts as their primary structural component. The safety level depends directly on welding quality which the UT/MT flaw detection system measures by its pass rate.

We employ multi layer multi pass robotic submerged arc welding for plate bevel welding above 30mm thickness to ensure quality control.

Core Process Points of Thick Plate Welding

Preheating: Preheatingt to 250℃ not only makes the tempeture differences during welding smaller but also results in a stress free weld.

• Interpass Temperature Control: Keeping a watch on the level of temperature between passes 180-220℃ through continuous measuring is also done in order to prevent hot cracking.
• Stress Relief Treatment: Conducting stress relief after welding is a way to not only improve the strength of the joint but also extend the life of the equipment.

Standards and Guarantees for Non Destructive Testing

Using the above procedures, our custom heavy-gauge steel parts can come out of 100% UT/MT non-destructive testing that meets load bearing Class 1 requirements, and at the same time, the operation of the equipment remains stable.

Figure 3:​ Ultrasonic inspection of welds on a metal part for quality assurance.

How To Plan Tolerances For Large Scale Thick Plate Fabrication?

In large scale thick plate fabrication , parts that are ultra large and have a length of more than 6 meters are very likely to develop measurement errors due to their own weight, which will eventually cause assembly failure in the end.

This is a very big problem for ordinary contract manufacturers, in fact, professional measurement methods are indispensable.

Measurement Equipment and Methods for Extra Large Thick Plates

We have implemented the use of FARO laser trackers to perform 3D inspection of the customized parts that are over 6 meters in length, in this way, we are able to accurately record the dimensional data that are not affected by the weight induced deformation, thus our measurements are guaranteed to be precise.

Dimensional Tolerance Control Standards and Customer Benefits

We have the capability to keep the dimensional tolerances well controlled within the reasonable limits:

The linear tolerance of 1.0mm can be maintained within a length of 5 meters, the bolt hole position tolerance is 0.2mm therefore the assembly can be completed successfully at the first time which, in turn, will help the customers to save their debugging time and costs.

Figure 4:​ A technical drawing of a bent metal part with fabrication tolerances.

How To Choose Economical Thick Plate Steel Cutting And Bending​ For Heavy Machinery?

After thick plate steel cutting and bending, anti-corrosion treatment determines the service life of the parts. Different wear environments require corresponding anti-corrosion technologies. We compare the cost-effectiveness of the processes based on working conditions and provide economic solutions.

Comparison of Anti-corrosion Processes in Different Corrosive Environments

Examples of Anti-corrosion Processes in Extreme Environments

When we were dealing with the foundation of our offshore drilling platform, after cutting and bending the thick plate steel, we shot blasted the parts to Sa2.5 standard. Then, in order to guarantee a service life of more than 15 years, we applied a combined anti corrosion method of powder coating + zinc-rich primer.

How Does LS Manufacturing Optimize Costs In Heavy Duty Metal Fabrication?

High costs in heavy duty metal fabrication are at the center of our clients' worries. Lowering prices is only one way many processors try to cut costs. We focus on improving the whole process, where we keep accuracy, help our clients' prices and their cost effectiveness.

Cost Optimization of Raw Material Procurement Strategy

Our main raw material cost optimization strategies are:

1. Direct Raw Material Sourcing: By directly sourcing from the leading worldwide steel mills, we avoid the extra costs that come from distributors, this way we manage to reduce the cost by 10%-15%.
2. Nesting Optimization: Using sophisticated nesting software leads to a significant increase of material utilization rate i.e. from 75% to 88%, which in turn cuts down the material waste and costs.

Core Methods for Production Efficiency Optimization

Using a cutting edge nesting software to accurately position the heavy plates can increase material utilization from a mere 75% to 88%, which is far above the industry average, leading to a reduction in material wastage and consequently a drop in costs.

Not only that, but this lean production method also results in the heavy duty metal fabrication delivery time being shortened by approximately 30% on average.

Additionally, it enables our international clients to discover more competitive pricing solutions when they conduct price comparisons, thus directly giving a boost to the project conversion rates.

How To Improve Fatigue Life With Custom Thick Plate Steel Service?

The durability of the whole machine under fatigue conditions is largely determined by how the custom thick plate steel service is processed. In case of high frequency vibrations of heavy equipment, the occurrence of cracks due to the excessive residual stress in the components is quite easy. Skilled workmanship is one of the ways to get rid of such a threat effectively.

Residual Stress Removal Ways and Their Impacts

We perform stress relief by means of large scale automatic annealing furnaces.

Our interventions will hugely cut down the welding residual stress level to the tune of 70% while at the same time ensuring that the stress within the components is evenly distributed thereby lessening fatigue cracking from its source and also making the structure more stable.

Welding and Bending Processes Re-Designed and Re-Implemented

• Welding Upgrade: Robotic multi layer, multi pass welding is capable of reducing the welding defects while at the same time enhancing the fatigue resistance of the joints.
• Bending Control: Careful selection of bending radii avoids stress concentration in the localized areas and hence fatigue cracking should be minimized.

Thick plate parts processed by us can increase the fatigue life of the entire machine by more than 120%. High standard custom thick plate steel service can help customers save maintenance costs and improve their reputation. Contact us for technical evaluation.

LS Manufacturing Case: Customizing 45mm Reinforced Vibration Screen Side Plates For Global Mining Giants

Real-life examples are probably the best way to showcase what we can do in the heavy-gauge sheet metal fabrication industry. Recently, the tailored 45mm vibrating screen side plates we proposed to an Australian mining giant not only helped them overcome their difficulties but also cemented a fruitful partnership.

Major Issues of the Customer:

The Australian mining equipment manufacturer's original supplier of 45mm thickness HARDOX side plates underwent fatigue fracture after only 2000 hours of operation.

Besides the fracture, a deviation of 3mm in hole position resulted in difficulty during assembly and increased maintenance costs. Desperate for a solution, the company turned to us for a specialized fabrication solution.

LS Manufacturing Solution

1. We formed an engineering squad to create a specially tailored heavy-gauge sheet metal fabrication system that would cater to the high frequency vibration, wear resistance, and load bearing aspects of vibrating screen side plates.
2. We not only dropped the original supplier's partial hot bending process but also used a 1600-ton cold bending process instead. This kept the original physical properties of the HARDOX steel plate intact and eliminated the material performance degradation due to hot bending, thus fixing the fatigue fracture problem from its source.
3. Automated precision drilling is carried out entirely by a large gantry machining center, which together with real time laser tracking, makes it possible to keep the hole spacing error within 0.2mm, thus solving the assembly problems.
4. Adopting the robot multi-layer and multi pass submerged arc welding process, full transmission testing is carried out on the welding joints of the side plates to ensure the strength of the welding joints. At the same time, stress relief annealing treatment is carried out to reduce residual welding stress by 70%, further improving the fatigue resistance of the side plates.

Results and Value:

The solution has produced impressive results: the lifespan of the side plates has been extended from 2000 hours to over 6500 hours (a 225% improvement), hole positioning is now perfectly accurate, assembly efficiency has risen by 50%, and the overall unit cost has dropped by 35%, which has resulted in a long term cooperation agreement with the client.

If you also face problems such as cracking and dimensional deviations in thick plate processing, please view the detailed case report and contact us to customize a customized solution.

FAQs

Q1: What is the maximum thickness of steel plate that LS Manufacturing can process for bending?

We have a 2000-ton large scale CNC bending machine, and at present, we can stably perform precision bending and forming services on steel plates as thick as 80mm. This capability allows us to meet the heavy duty processing requirements of mining, marine engineering, and other industries.

Q2: What materials does your custom thick plate steel service support?

Our custom thick plate steel service is flexible with materials, including carbon steel (A36, Q355B), stainless steel (304/316L), wear resistant steel (Hardox series), and high strength plate (Q690D), to fit the different needs of various applications.

Q3: What is the typical tolerance range for processing large scale thick plate parts?

During large scale thick plate manufacturing within a 5-meter length, we can generally manage the linear tolerance within 1.0mm and the bolt hole position tolerance within 0.2mm, resulting in zero deviation when performing on site assembly.

Q4: How can I obtain a real time processing quote from LS Manufacturing?

Just upload your PDF or STEP drawings, and our senior engineers will contact you within 24 hours with a technical quotation that includes their process recommendations. The pricing is open, and there are no hidden costs.

Q5: Do you provide stress relieving heat treatment after welding of heavy plates?

Indeed, we have a very large automated annealing furnace that is capable of vibration aging or thermal aging treatment for custom heavy gauge steel parts. It is a rather effective way to cut down on residual welding stress by as much as 70%, ultimately preventing fatigue crack development.

Q6: How rough is the surface finish after thick plate cutting by LS Manufacturing?

Our 10,000 watt laser facility ensures our surface roughness is controlled at around Ra 12.5, which is a better performance than the traditional oxy-acetylene cutting. The cut edges can be welded directly without the need of secondary grinding.

Q7: Are you able to fabricate only welded structural components over 10 ton?

Yes, of course. Our heavy-duty workshop has a 32 ton overhead crane lifting system as one of its equipment. This system has been tailor made for industrial thick steel sheet fabrication and is capable of handling, with ease, the processing and transfer of single welded structural components weighing over 10 tons.

Q8: Why LS Manufacturing, not an ordinary small manufacturer?

It is due to the fact that we have the production line which covers the whole process from cutting to welding, hence no need for outsourcing and controlling quality and delivery efficiency by over 40%. Besides, we give full process customization services and are fully capable of heavy-gauge sheet metal fabrication.

Summary

Heavy-gauge sheet metal fabrication is all about the perfect harmony of precision, materials, and methods. Details are what make the difference in safety and durability of the product.

LS Manufacturing combines the best equipment and a skilled engineering team to tackle the everlasting issues of heavy gauge sheet metal fabrication. As a result, LS Manufacturing has grown into a reliable partner of high end customizations for the industrial clients all over the world.

If you want a custom thick plate steel service supplier with a high level of precision, you can upload your drawings. We will do a free DFM analysis and provide you with a factory direct quote. It is our intention to help your projects through quality services.

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🌐Website: https://lsrpf.com/

Disclaimer

The contents of this page are for informational purposes only. LS Manufacturing services There are no representations or warranties, express or implied, as to the accuracy, completeness or validity of the information. It should not be inferred that a third-party supplier or manufacturer will provide performance parameters, geometric tolerances, specific design characteristics, material quality and type or workmanship through the LS Manufacturing network. It's the buyer's responsibility. Require parts quotation Identify specific requirements for these sections.Please contact us for more information.

LS Manufacturing Team

LS Manufacturing is an industry-leading company. Focus on custom manufacturing solutions. We have over 20 years of experience with over 5,000 customers, and we focus on high precision CNC machining, Sheet metal manufacturing, 3D printing, Injection molding. Metal stamping,and other one-stop manufacturing services.
Our factory is equipped with over 100 state-of-the-art 5-axis machining centers, ISO 9001:2015 certified. We provide fast, efficient and high-quality manufacturing solutions to customers in more than 150 countries around the world. Whether it is small volume production or large-scale customization, we can meet your needs with the fastest delivery within 24 hours. choose LS Manufacturing. This means selection efficiency, quality and professionalism.
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