Crack Repair of A Press Frame-3500 Ton Capacity RA Power Solutions: 44 Years Of Experience in Meta
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RA Power Solutions was approached by a leading automobile manufacturing company based in North India to execute the repair of a damaged main frame body of 3500 Ton Press, supplied, installed, and maintained by a renowned Japanese company. RA Power Solutions team of engineers visited the plant during the shutdown and following was observed. The main frame of the 3500 Ton Press, which developed crack was the backbone of the plant as the complete body of the vehicles including doors/bonnet etc were formed on the press. The company was asked to disassemble all the parts, adjacent to the area where the crack was developed. The crack area of the press was thoroughly cleaned. Paint and red oxide were completely removed by the chemicals. The hardness test of the crack area of the press was undertaken. The MPI test was done on the crack area where a crack having a horizontal profile measuring 400 MM was observed. The crack was through the complete width of the frame plate having thickness of 40 MM. All the technical parameters including load characteristics of 3500 Ton Press were studied by the RA Power Solutions engineers and it was decided to go ahead with the repair of crack by metal stitching and metal locking process.
Metal Stitching
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We offer metal stitching. Metal stitching is a precise mechanical method of making permanent repairs to broken casting and machine parts. No heat is used, thus no stresses are introduced and no post-repair machining is necessary to correct misalignment and warpage. Since there is no heat, metal locking repairs can be made in restricted areas where flames or welding arc is prohibited repairs are done on location in the plant, without the necessity of major dis-assembly. Maintaining production and reducing down time of broken equipment presents many new challenges. Solutions are arrived at after a careful analysis and then applying our experience to make a proper, dependable repair. The quality and craftsmanship thus achieved have earned for us the recommendation and endorsement of equipment manufacturers, insurance underwriters and inspection services. procedure drilling fixture is attached of right angles to the crack. A hole pattern is drilled and this is repeated at intervals from ¾ to 1 ¼ inches apart. Metal between each drilled hole is removed by ripping it away with pneumatic tools to form a slot. The stock thus removed is narrower than the drilled hole, thus forming a serrated opening. Preformed locks of high tensile alloy are inserted in to the slot. These locks are peened into the slots, one on top of the other, to a depth limited by the casting thickness and determined by the strength required. After the locks are installed, holes are drilled, tapped and threaded, fasteners are applied. These are spotted along the entire length of the crack, overlapping one another. Their purpose, in part, is to fill the fracture with new metal and provide a pressure seal. Entire repair area is peened flush and finish ground.
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