疲劳条件下整机的耐久性很大程度上取决于定制厚板钢材服务的加工方式。 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.
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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
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.
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.
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.
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.
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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.
常见问题解答
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.
摘要
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.
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.不应推断第三方供应商或制造商将通过 LS Manufacturing 网络提供性能参数、几何公差、具体设计特征、材料质量和类型或工艺。 It's the buyer's responsibility. Require parts quotation Identify specific requirements for these sections.Please contact us for more information.
LS 制造团队
LS Manufacturing 是一家行业领先的公司。专注于定制制造解决方案。 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.我们为全球150多个国家的客户提供快速、高效、高质量的制造解决方案。无论是小批量生产还是大规模定制，我们都能以最快的24小时内交货满足您的需求。选择LS制造。 This means selection efficiency, quality and professionalism. To learn more, visit our website:www.lsrpf.com.
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