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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 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.
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.
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 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 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.
Galbiati Group has recently produced and built for one of the most important Italian companies, with destination Turkey, a tubes spot welding machine made by spiral calendering.
Spiroidal tubes welding line technical details:
• Tube diameter = from 508 mm to 1625 mm.
• Tubes max. length = 24 m
We have recently performed third-party mechanical machining operations for a large base and head. These components, for their size and length, are perhaps the largest ever made.
The two components, base and head for six-piston compressor made of spheroidal cast iron, machined separately, are intended for a compressor station installed on systems fixed to the ground with the purpose of compressing the gas for its transition from solid to liquid state.
The members of ASSIOT – Associazione Italiana Costruttori Organi di Trasmissione e Ingranaggi, on the occasion of their Annual Assembly, have elected Assunta Galbiati as their new President, designating her to guide the Association for the next two years. Assunta Galbiati has been a member of the ASSIOT Management Board since 2012 and is the owner of the company Galbiati Group, specialized in the supply of large scale mechanical works on behalf of third parties, the construction of special gear motors for the steel industry, lamination systems, power transmissions, the cement industry, rubber industry, planetary gears for TBM rotating heads, etc.
We have designed and built this segment erector with a maximum capacity of 2.3 tons, intended for a Tunnel Boring Machine that will be used for an important excavating project inLos Condores, Chile.
The segment positioning erector is composed of
a fixed structure and a moving one, both made of electro-welded structural metalwork 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.
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.
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.
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.
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.
We have designed and built this segment erector with a maximum capacity of 2.3 tons, intended for a Tunnel Boring Machine that will be used for an important excavating project inLos Condores, Chile.
The segment positioning erector is composed of
a fixed structure and a moving one, both made of electro-welded structural metalwork 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 members of ASSIOT – Associazione Italiana Costruttori Organi di Trasmissione e Ingranaggi, on the occasion of their Annual Assembly, have elected Assunta Galbiati as their new President, designating her to guide the Association for the next two years. Assunta Galbiati has been a member of the ASSIOT Management Board since 2012 and is the owner of the company Galbiati Group, specialized in the supply of large scale mechanical works on behalf of third parties, the construction of special gear motors for the steel industry, lamination systems, power transmissions, the cement industry, rubber industry, planetary gears for TBM rotating heads, etc.
We have recently performed third-party mechanical machining operations for a large base and head. These components, for their size and length, are perhaps the largest ever made.
The two components, base and head for six-piston compressor made of spheroidal cast iron, machined separately, are intended for a compressor station installed on systems fixed to the ground with the purpose of compressing the gas for its transition from solid to liquid state.
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.
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.