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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.
This component was machined from a solid block of 17-4 PH steel. All milling and drilling was done on a KPMP CNC mill.
For additional information, visit our website at www.kustomprecision.com
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.
Aerospace and aeronautic opportunities: Manufacturing in Mexico for the Maquiladora Industry -American Industries Group, operation start-up partner. www.aerospace.americanindustriesgroup.com
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.
Complete supply of a straightening machine for coil cutting line.
We have recently supplied one complete straightening machine having a total weight of about 7,000 kg, intended to be inserted in an existing coil machining and processing system.
Usually straightening machines are placed at the inlet of the coil cutting line to carry out a first extension of the strip fibres and to break the surface calamine chips. In fact straightening machines are designed to provide high elasticity and plasticity to the material and, in combination with the action of the flattening machine, to obtain the strip flatness.
The straightening machine in question is intended for processing materials such as special steels and composites: molybdenum, tungsten, chromium etc.
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.
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.
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.
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.
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.
We have recently built the largest segment erector, for its size and weight, we have ever made.
Galbiati has designed and built this segment erector with a maximum capacity of 9.7 tons, intended for a Tunnel Boring Machine that will be used for an important project called "Hiroshima Project" in Japan. The TBM for which the erector has been built, with a 13.2 meter diameter cutter head, will have the task of creating a tunnel for the construction of lane 5 of the Hiroshima expressway in Japan.
The segment positioning erector, in question, consisting of the translating/rotating ring with rollers and the pick-up unit, is made up of a single moving structure, made of electro-welded structural metalwork and machined on machine tools.
We started with the mechanical machining of 4 sectors that, assembled, make up the rotating ring of the erector with a diameter of 13.5 meters. Given the size and weight, the rotating ring of the erector made assembly operations difficult, so that it has not been possible to position the erector vertically.
We have supplied to the end customer, 11 planetary drives completely refurbished, sized for a nominal torque of 170 kNm, in a strong structure suitable for heavy duty and equipped with water recirculating chamber for oil cooling. TBM slow head driving pinions, module 25 mm, carburized hardened and with ground tooth profile. The weight of each planetary drive is 2,980 kg.
Regarding the revamping operations performed on the individual drives: we carried out the dimensional checks to establish wear and deformation, the non-destructive checks to check the condition, using qualified operators, very high precision instrumentation, and a ZEISS MMZ-G 30 60 25 checking machine. To complete the overhaul of each planetary drive, we performed the functional test with measurement of temperatures, noise, vibrations, with the release of the relative test report.
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
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.
Precision Machining program tour with Dean Tommy Cannon, DCC President Dr. Carlyle Ramsey, Troy Simpson, Gary Hopkins and Jim Krasula.
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 engineering and construction of a large Pinion stand mill drive (Main drive) for a hot rolling mill, equipped with 1 x 7000 kW motor. The gears and shafts consist of bi-helical pinions made of 18CrNiMo7-6 steel, hardened, casehardened and ground to meet the standards of quality DIN 3961 Class 6. Gear teeth undergo profile correction to optimize power transmission and contact between mating surfaces of the gear pair. In addition, the girth gear is realized in electro-welded structure in 30CrNiMo8, while the lower shaft is realized in 42CrMo4.