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The Galbiati Group recently undertook a project to recondition two gear reducers for screw down drives installed in an old plant operating at Mariupol in the Ukraine.
The engineering was entrusted to renowned industry leader Primetals Linz, whilst the machines themselves are the property of end customer Metinvest Engineering LLC, also located in the Ukraine at Dnipropetrovsk.
The reconditioning operation concerns a pair of gear reducers coupled to screw down drives in an assembly weighing 18 tons overall, which includes the support frame, auxiliaries, brakes, auxiliary geared motors, etc. The gear reducers consist in two symmetrical components of around 9000 kg each.
Machined Fabrications Ltd , is a machining & fabrication company.Our extensive workshops and comprehensive range of Large CNC machine tools, modern tooling, and a highly skilled workforce support our commitment to consistently high standards of product and service.
The ability to complete the fabrication, machining, and surface finishing within our own plant enables us to provide a rapid, cost effective service allowing us to meet the specifications and demanding schedules required by our customers
Machined Fabrications Ltd. Machined Fabrications are very proud to announce that we have now attained the Steel Construction Certificate Scheme (SCCS) Weld Certificate and Factory Production Control Certificate confirming compliance and effective implementation of the Management System in accordance with the requirements of BS EN1090-1:2009, this falls in line with the new legal obligation that all fabricated structural steelwork is CE Marked.We also have 4 large CNC machine shops that offer a wide range of large cnc machines at Machined Fabrications Ltd, Ufone Precision Engineers Ltd and Adelaide Engineering Co Ltd & Askey Precision Engineering .
Our extensive workshops and comprehensive range of CNC machine tools, modern tooling, and a highly skilled workforce support our commitment to consistently high standards of product and service.
The ability to complete the fabrication, machining, Our Large Cnc machines are operated by our highly skilled, experienced engineers excel at milling & turning. We have one of the largest ranges of modern CNC lathes in the country and these are available for sub-contract work.
At Machined Fabrications we have been providing the Power Generation Oil & Gas and Petrochemical industry with the highest quality CNC Machining Services.
Large CNC Machining / Large CNC Milling /
Precision CNC Machining
Hannover Messe 2018 once again has been confirmed to be a global reference point for the digital transformation of industries. The main theme was once again the global transition to Industry 4.0. Extensive value creation networks, new forms of human-machine collaboration and the growing integration of artificial intelligence into production, digitization and connectivity operations were the main topics that were once again disclosed in Hanover.
The technology, the interaction of human beings and IT machines, as the main element of this global event, which translates into a huge competitive advantage for the entire manufacturing sector.
With the "Integrated Industry - Connect & Collaborate” motto, a total of 210,000 visitors and 5,800 exhibitors took the opportunity to explore innovations at the fair. More than 70,000 of them came from abroad: China with a total of 6,500 visitors, followed by the Netherlands (5,300), Poland (2,700), the United States (1,700) and Mexico (1,400). As an official partner country, Mexico has emerged as an innovative business partner.
Many visitors and prominent decision makers had the opportunity to generate new business contacts and transfer knowledge and skills.
Galbiati Group, present with the Mechanical processing and Gear reducers divisions, for the first time in the Industrial Supply pavilion (Hall 4, Stand E11), has proved to be very successful compared to previous years, obtaining interesting contacts and meeting new business opportunities.
Hannover Messe 2018 once again has been confirmed to be a global reference point for the digital transformation of industries. The main theme was once again the global transition to Industry 4.0. Extensive value creation networks, new forms of human-machine collaboration and the growing integration of artificial intelligence into production, digitization and connectivity operations were the main topics that were once again disclosed in Hanover.
The technology, the interaction of human beings and IT machines, as the main element of this global event, which translates into a huge competitive advantage for the entire manufacturing sector.
With the "Integrated Industry - Connect & Collaborate” motto, a total of 210,000 visitors and 5,800 exhibitors took the opportunity to explore innovations at the fair. More than 70,000 of them came from abroad: China with a total of 6,500 visitors, followed by the Netherlands (5,300), Poland (2,700), the United States (1,700) and Mexico (1,400). As an official partner country, Mexico has emerged as an innovative business partner.
Many visitors and prominent decision makers had the opportunity to generate new business contacts and transfer knowledge and skills.
Galbiati Group, present with the Mechanical processing and Gear reducers divisions, for the first time in the Industrial Supply pavilion (Hall 4, Stand E11), has proved to be very successful compared to previous years, obtaining interesting contacts and meeting new business opportunities.
At A&A Machine & Fabrication, we specialize in precision machining and industrial fabrication services. - www.aagroup.com
Galbiati Group has recently manufactured a large gear wheel with relative carburized pinion, intended to be positioned inside a twin drive gearbox, for R1-F1 rolling mill control.
Some steps of the gear wheel machining are shown below.
Initially, on the gear wheel, welding operations (WPS) were carried out on high-strength steels, respecting the temperature parameters of the aforesaid materials.
The welds were finally certified thanks to the execution of magnetic testing, ultrasonic testing and die penetrant inspection.
Since the gear wheel is made of electro-welded material, made of high-strength steel, at the end of the welding, thermal stress relieving treatments have been carried out to avoid possible materials deformation.
The wheel gears are made with a protuberance hob, then ground and hardened on the surface with a correct profile. Gear quality equal to 6 DIN-3962.
The gear wheel was at last clamped on a slow shaft (diameter 800 mm, length 3.500 mm), always made at the Galbiati Group workshops.
We have built, based on the end customer's drawings, two shears for an important steel mill with final destination in Oman.
These are two shears: one inlet, and one outlet for aluminium cutting for hot rolling mill line.
The inlet shear, placed in the plant before the rolling mill stand, is used to square off the coil edge cut in the correct way for the subsequent threading operation. Also known as an "emergency shear", it cuts the ends of the band so that the coil does not get stuck in the first rolling mill stand, avoiding to stop the plant.
The output shear, placed in the plant after the rolling mill stand, is rotary with the function of establishing the lengths of the coil, dividing the end of the previous reel from the head of the next reel and cutting some pieces of the tape to allow it to insert in the winding reel.
Not done by Ballos Precision Machine, just a fine example of a beautiful performance parts machining.
A&A Machine & Fabrication: We specialize in precision machining and industrial fabrication services. We offer full service precision machining to a variety of industries including the petrochemical industry. Our industrial fabrication services include custom applications, ASME code fabrication, repairs, maintenance and new manufacturing services. Contact us to learn more about our precision machining and industrial fabrication services or one of our other many services.
The Galbiati Group recently undertook a project to recondition two gear reducers for screw down drives installed in an old plant operating at Mariupol in the Ukraine.
The engineering was entrusted to renowned industry leader Primetals Linz, whilst the machines themselves are the property of end customer Metinvest Engineering LLC, also located in the Ukraine at Dnipropetrovsk.
The reconditioning operation concerns a pair of gear reducers coupled to screw down drives in an assembly weighing 18 tons overall, which includes the support frame, auxiliaries, brakes, auxiliary geared motors, etc. The gear reducers consist in two symmetrical components of around 9000 kg each.
Galbiati Group has recently manufactured a 7,800 mm diameter radio telescope in consortium with the company EIE GROUP, an engineering company and an excellence in the Italian industrial landscape in the astronomy sector.
Galbiati collaborated with the Turkish university body, ISIK UNIVERSITY, and the AMOS company, specialized in the design and production of high precision mechanical opto systems for the space industry and for astronomy, for the production and construction of a new 4 meter radio telescope for the Eastern Anatolian Observatory in Turkey. DAG (Dogu Anadolu Gözlemevi, Turkish Eastern Anatolia Observatory) is a project funded entirely by the Turkish Ministry of Development and by the Atatürk University of Astrophysics Research Telescope - ATASAM.
The Galbiati Group recently undertook a project to recondition two gear reducers for screw down drives installed in an old plant operating at Mariupol in the Ukraine.
The engineering was entrusted to renowned industry leader Primetals Linz, whilst the machines themselves are the property of end customer Metinvest Engineering LLC, also located in the Ukraine at Dnipropetrovsk.
The reconditioning operation concerns a pair of gear reducers coupled to screw down drives in an assembly weighing 18 tons overall, which includes the support frame, auxiliaries, brakes, auxiliary geared motors, etc. The gear reducers consist in two symmetrical components of around 9000 kg each.
Our supply contract covered the design and construction of gear reducers for an Edger drive installed in a hot rolling mill, providing three reduction ratios, with self-supporting vertical twin motor power transmission. Two twin mirror-image reduction gear units, with high-stiffness connecting flange. The Edger drive parallel shaft gear reducer is a vertically mounted unit with two input shafts and two output shafts. The gear trains incorporate shafts, gear wheels and pinions with helical teeth made of 18CrNiMo7-6 steel, hardened, casehardened and ground to meet the standards of DIN grade 6. Low speed shafts made of 42CrMo4 steel.
The Galbiati Group recently undertook a project to recondition two gear reducers for screw down drives installed in an old plant operating at Mariupol in the Ukraine.
The engineering was entrusted to renowned industry leader Primetals Linz, whilst the machines themselves are the property of end customer Metinvest Engineering LLC, also located in the Ukraine at Dnipropetrovsk.
The reconditioning operation concerns a pair of gear reducers coupled to screw down drives in an assembly weighing 18 tons overall, which includes the support frame, auxiliaries, brakes, auxiliary geared motors, etc. The gear reducers consist in two symmetrical components of around 9000 kg each.
Galbiati Group has recently designed and built two segment erectors with a maximum capacity of 4.5 tons, intended for a Tunnel Boring Machine that will be used for an important excavating project in the Qingdao subway in China.
The two segment positioning erectors are made up of a fixed structure and a moving one, both made of electro-welded structural metalwork, flattened and machined on machine tools. The fixed part consists of two longitudinal beams on which the sliding guides, made of wear-resistant material, are mounted. The moving part, instead, comprises the translating, rotating ring and the pick-up unit.
The function of the two TBM erectors is to hook, lift and position the concrete segments to make the tunnel supporting structure.
The main movements of the two erectors consist of:
• an axial translation of the moving part;
• a rotation of the rotating ring and of the pick-up unit along the translation axis;
• a radial translation of the pick-up unit only.
We have built, based on the end customer's drawings, two shears for an important steel mill with final destination in Oman.
These are two shears: one inlet, and one outlet for aluminium cutting for hot rolling mill line.
The inlet shear, placed in the plant before the rolling mill stand, is used to square off the coil edge cut in the correct way for the subsequent threading operation. Also known as an "emergency shear", it cuts the ends of the band so that the coil does not get stuck in the first rolling mill stand, avoiding to stop the plant.
The output shear, placed in the plant after the rolling mill stand, is rotary with the function of establishing the lengths of the coil, dividing the end of the previous reel from the head of the next reel and cutting some pieces of the tape to allow it to insert in the winding reel.
Galbiati Group has recently manufactured a large gear wheel with relative carburized pinion, intended to be positioned inside a twin drive gearbox, for R1-F1 rolling mill control.
Some steps of the gear wheel machining are shown below.
Initially, on the gear wheel, welding operations (WPS) were carried out on high-strength steels, respecting the temperature parameters of the aforesaid materials.
The welds were finally certified thanks to the execution of magnetic testing, ultrasonic testing and die penetrant inspection.
Since the gear wheel is made of electro-welded material, made of high-strength steel, at the end of the welding, thermal stress relieving treatments have been carried out to avoid possible materials deformation.
The wheel gears are made with a protuberance hob, then ground and hardened on the surface with a correct profile. Gear quality equal to 6 DIN-3962.
The gear wheel was at last clamped on a slow shaft (diameter 800 mm, length 3.500 mm), always made at the Galbiati Group workshops.
Hannover Messe 2018 once again has been confirmed to be a global reference point for the digital transformation of industries. The main theme was once again the global transition to Industry 4.0. Extensive value creation networks, new forms of human-machine collaboration and the growing integration of artificial intelligence into production, digitization and connectivity operations were the main topics that were once again disclosed in Hanover.
The technology, the interaction of human beings and IT machines, as the main element of this global event, which translates into a huge competitive advantage for the entire manufacturing sector.
With the "Integrated Industry - Connect & Collaborate” motto, a total of 210,000 visitors and 5,800 exhibitors took the opportunity to explore innovations at the fair. More than 70,000 of them came from abroad: China with a total of 6,500 visitors, followed by the Netherlands (5,300), Poland (2,700), the United States (1,700) and Mexico (1,400). As an official partner country, Mexico has emerged as an innovative business partner.
Many visitors and prominent decision makers had the opportunity to generate new business contacts and transfer knowledge and skills.
Galbiati Group, present with the Mechanical processing and Gear reducers divisions, for the first time in the Industrial Supply pavilion (Hall 4, Stand E11), has proved to be very successful compared to previous years, obtaining interesting contacts and meeting new business opportunities.
We have recently performed for an important international leading customer, mechanical machining of 8 shoulders for rolling mill stands.
The mechanical machining of each shoulder for rolling mill stands is carried out on CNC machine tools with up to 5 next-generation controlled axes. The final geometry, in accordance with the dimensional tolerances, of flatness, parallelism and orthogonality of the work and support surfaces is controlled with the new Faro Vintage Laser Tracker system.
The mechanical roughing of each shoulder reaches a length over 12 m, a height over 4.5 m, and a maximum weight on the rotating table over 120 tons. Depending on the geometry of the raw steel casting, the removal of material, to achieve the finished shoulder ready to be assembled, can also exceed 10% of the raw shoulder weight.
Complete mechanical processing cycle performed:
• milling
• drilling
• dimensional testing using the Vintage Laser Tracker.
Our supply contract covered the engineering and manufaturing of a large pinion stand drive for a hot rolling mill, equipped with 1 x 7000 kW motor, a single horizontal input shaft and twin output shafts. The gears and shafts consist of double helical pinions made of 18CrNiMo7-6 steel, hardened, casehardened and ground to meet the standards of DIN 3961 grade 6. Gear teeth undergo profile correction to optimize power transmission and contact between mating surfaces of the gear pair. In addition, the pinion shafts are fitted with ring seals designed to prevent wear.
Galbiati Group has recently manufactured a 7,800 mm diameter radio telescope in consortium with the company EIE GROUP, an engineering company and an excellence in the Italian industrial landscape in the astronomy sector.
Galbiati collaborated with the Turkish university body, ISIK UNIVERSITY, and the AMOS company, specialized in the design and production of high precision mechanical opto systems for the space industry and for astronomy, for the production and construction of a new 4 meter radio telescope for the Eastern Anatolian Observatory in Turkey. DAG (Dogu Anadolu Gözlemevi, Turkish Eastern Anatolia Observatory) is a project funded entirely by the Turkish Ministry of Development and by the Atatürk University of Astrophysics Research Telescope - ATASAM.
Our supply contract covered the engineering and manufaturing of a large pinion stand drive for a hot rolling mill, equipped with 1 x 7000 kW motor, a single horizontal input shaft and twin output shafts. The gears and shafts consist of double helical pinions made of 18CrNiMo7-6 steel, hardened, casehardened and ground to meet the standards of DIN 3961 grade 6. Gear teeth undergo profile correction to optimize power transmission and contact between mating surfaces of the gear pair. In addition, the pinion shafts are fitted with ring seals designed to prevent wear.
Based on original designs of the end customer, Galbiati has produced and supplied to a known Indian steel mill two spare segments for a continuous casting plant.
The thickness of the casting sheet is precisely calibrated by special high pressure hydraulic cylinders fed by stainless steel pipes mounted on the segments.
Most of the mechanical, hydraulic components of the segments for continuous casting have been purchased by the most qualified European manufacturers.
A complete pre-assembly of the segments for continuous casting was carried out at the assembly department of Officine Galbiati and a final test was carried out with the full satisfaction of the Indian end customer’s inspector.
A special maritime packaging has been designed and manufactured at the Galbiati workshop to allow the shipment of each segment for continuous casting completely assembled and therefore ready for quick assembly on site.
A technical and quality manager of the Galbiati staff was requested by the Indian customer for on-site supervision in order to reconfirm the maximum performance and the good operation of the segments for continuous casting.
Our supply contract covered the design and construction of gear reducers for an Edger drive installed in a hot rolling mill, providing three reduction ratios, with self-supporting vertical twin motor power transmission. Two twin mirror-image reduction gear units, with high-stiffness connecting flange. The Edger drive parallel shaft gear reducer is a vertically mounted unit with two input shafts and two output shafts. The gear trains incorporate shafts, gear wheels and pinions with helical teeth made of 18CrNiMo7-6 steel, hardened, casehardened and ground to meet the standards of DIN grade 6. Low speed shafts made of 42CrMo4 steel.