Why Guaranteeing Machining Stability/precision Is A Great Challenge on Heavy-duty Beam End Facing Machine?

Topic of this Blog on Metal Structure Flange Milling Machine:

1. Usage of H Beam End Face Milling Machine: 

1) The other names include: 

a) Metal Structure Flange Milling Machine;

b) Welding Structure End Face Milling Machine;

c) H Beam End Facing Machine... , 

Is used for performing end face milling on structure members of various sizes and structure (H Beam/I Beam/ BOX Beam/ Pipe Structure Member…, etc.);

2. Specifications of Metal Structure Flange Milling Machine: 

1) Common Seen: The general used workpiece size is 800 ~2,000 mm vertical end facing stroke, the corresponding models of H Beam End Face Milling Machine are DX08xx to DX20xx; 

2) Heavy duty H Beam End Face Milling Machine: 

a) Challenge: For those workpieces with valid 3,000 mm milling stroke and higher, especially 4,000 mm and above (DX30xx ~ DX60xx), design and manufacture on such heavy duty H Beam End Face Milling Machine test capability/ experience/ strength of the End Facing Machine producers;

b) Here we use the DX4080/ DX6080 heavy duty H Beam End Face Milling Machine as example to explore the challenging process;

3. Topics Here on H Beam End Face Milling Machine:

• Usage of Welding Structure End Face Milling Machine;

• Definition on heavy duty H Beam End Face Milling Machine and its features;

• Wuxi JACK Advantages on Design and Manufacture of heavy duty Metal Structure Flange Milling Machine

A. Usage of Welding Structure End Face Milling Machine:

1. Application of Metal Structure Flange Milling Machine: 

1) Applied Sectors: H Beam End Face Milling Machine is for milling end face of Steel Structure Members/ Pipes/ Tanks used in industries of Steel Structure/ Ship Building/ Boiler/ Oil and Gas Pipeline, etc.;

2) Equipment Nature: Not only working as Welding and Cutting Equipment in Steel Structure, Metal Structure Flange Milling Machine can also be applied as rough stage general purpose machining equipment;

2. Common Specifications of Metal Structure Flange Milling Machine: 

1) Depending on workpiece size, especially its height or diameter, these Welding Structure End Face Milling Machine have series of models from as small as DX0810 (For end facing workpiece of 800mm height and 1,000mm width),

2) To as large as DX6080 (For acquiring end facing workpiece of 6,000mm height and 8,000mm width);

3. Development on Metal Structure Flange Milling Machine: 

1) Trend: Over the past 6~7 years, with more and more round section shape workpiece appear for end face milling, such as pipe/ tube/cylinder/ tanks,

2) CNC control Metal Structure Flange Milling Machine is used for better precision and higher efficiency end facing process, making the equipment a kind of powerful Pipe End Face Milling Machine of various sizes:

3) Pipe/ special cross section working parts and Wuxi JACK CNC Metal Structure Flange Milling Machine: (Fig.1) 

B. Definition on Heavy duty H Beam End Face Milling Machine and its Features:

1. Critical Index on Large Size Metal Structure Flange Milling Machine: 

1) Specification: 3,000 mm height vertical end face milling stroke is threshold for distinguishing common size and large size Welding Structure End Face Milling Machine;

2) Currently the models of DX3030/ DX3035/DX3535 End Facing Machine… are popular in the market, because majority of medium large workpieces have its size falling within this scope;

Wuxi JACK DX3535 Large Welding Structure End Face Milling Machine works on large BOX Beam: (Fig.2)

2. Large H Beam End Face Milling Machine: 

1) Demand: Still further, there are around 5~10% very large size of heavy duty H Beam End Face Milling Machine in practical use, from DX4080 to DX5080 to DX6080;

2) For Customers: Such heavy duty H Beam End Face Milling Machine cater for specialized requirement from customers from Large Ship Building/ Bay Bridge Construction, etc.

3) Challenge on Large Models: As a Chinese saying going, “Quantitative change brings along quantitative change”. When developing and manufacturing such big size heavy duty End Face Milling Machine, what is the challenge to supplier of the H Beam End Facing Machine, and how to solve it?

C. Wuxi JACK Advantages on Design and Manufacture of heavy duty H Beam End Face Milling Machine:

1. Technical Features of Large Metal Structure Flange Milling Machine: 

Let’s start from the topic of feature and challenge on large size H Beam End Face Milling Machine:

 1) The most impressed characteristic with such “Big Man”, of course, is its excessive big dimension;

2) As we can see from the subject photo of this blog, which was taken in the year of 2011 for the DX4080 heavy duty H Beam End Face Milling Machine, it has total height of over 2 storeys (6,500mm) and 11,000mm long;

3) So, people working on it for installation/ commissioning and daily working need to climb up and down, or stand on the elevating stands all the while;

2. Difficult Points in Developing Large Scale Metal Structure Flange Milling Machine: 

1) As can be imagined, order to delivery on such large scale H Beam End Face Milling Machine, 

2) Including mechanical parts machining and assembling, transportation and on site installation at customer facility, are really hard and uneasy;

3. So, what is performance of Wuxi JACK on delivering such heavy duty H Beam End Face Milling Machine to customers?

4. Technical Superiorities of Wuxi JACK H Beam End Face Milling Machine: 

Same as Sheet Metal Steel Plate Edge Milling Machine, to get the best milling quality and efficiency, we improved design on H Beam End Face Milling Machine to better level: 

1) Unique Powerful Milling Head: Different from the general used milling head of 5.5kW and welded rail in industry by other companies, Wuxi JACK adopt milling head of 7.5kW/ 9kW/ 11kW;

7.5kW milling head in Wuxi JACK H Beam End Face Milling Machine: (Fig.3)

2) High precision ball bearing linear guideway, which is assembled onto machine bed by Wuxi JACK team, instead of welded onto machine bed by other suppliers, making end face milling process more efficient and good quality, while maintaining the same reasonable level of Welding Structure End Face Milling Machine price;

Heavy duty precise linear guide rail on Wuxi JACK H Beam End Face Milling Machine: (Fig.4)

5.  Superior Technology on Design and Manufacture Heavy Duty H Beam End Facing Machine:

1) At the same time, we have leading position in the field of developing large scase End Facing Machine:

2) Same as high rise building, increase in size and loading capacity for these Welding Structure End Face Milling Machine poses great challenge to machine manufacturer, and we overcome the difficulty thanks to our rich experience and advanced technology;

6. Actions on Guaranteeing Successful Delivery of the Welding Structure End Face Milling Machine are Listed below but not Limited to:

1) Before manufacture, during design stage, strict force analysis is made and validated with teamwork;

2) Based on rich experience of our engineering team, DFMEA (Design Failure Mode Effect Analysis) is made on H Beam End Face Milling Machine, to avoid occurrence of mistakes which should be avoided;

3) PFMEA (Process Failure Mode Effect Analysis) and Control Plan and Process Flow of the heavy duty H Beam End Face Milling Machine are also worked out and strictly implemented with team work;

4) All the structure members of the Welding Structure End Face Milling Machine are integrally machined, instead of pieced together, so as to get the best degree of integrity and strong structure;

5) Maintaining Continuous Improvement all the while --- From past experience and feedback from customers;

6) Work with professional transportation suppliers to make sure its safe and surefire conveying from Wuxi JACK to customer site…

7. The 1^st Set of Wuxi JACK Heavy duty End Facing Machine: 

1) In 2011, Wuxi JACK engineering team designed and made the heavy duty H Beam End Face Milling Machine of DX4080,

2) Capability: This large Metal Structure Flange Milling Machine takes the task on end face machining on metal structure beam, with cross section size up to 4,000mm by 8,000mm successfully;

3) Client: For a domestic shipbuilding customer. The Wuxi JACK DX4080 Metal Structure Flange Milling Machine has gained very positive feedback from them;

8. The Largest Metal Structure Flange Milling Machine in the Industry Produced by Wuxi JACK:

1) In 2018, Wuxi JACK successfully exported another set of DX6080 heavy duty Welding Structure End Milling Machine to Vietnam;

2) This large size Metal Structure Flange Milling Machine exhibits stable high standard performance from the date of put into operation.

Summary on DX Series H Beam End Face Milling Machine:

As a senior and good reputation professional producer in Welding and Cutting Machinery, including DX series H Beam End Face Milling Machine, Wuxi JACK always seeks on continuous improvement on our design, manufacture, and delivery high standard equipment to customers across the industry and globe.