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Welding Fixture, Hobbing Cutter, Heavy duty Edge Milling Machine, Special Welding Positioner, and Rolling Boring Machine


1. The Subject of this Page on Welding Fixture:

The 5 equipment introduced in this page can be summarized as “Welding Fixture”: Although not worked as welding equipment directly, these equipment plays key role in:
1) Making preparation on welding operation (Hobbing Cutter/ Heavy duty Edge Milling Machine/ Rolling Boring Machine);
2) Or serving as assistant unit during welding operation (Special Welding Positioner / Welding Fixture)


2. The common points of these Welding Fixture and Supporting Equipment are:

1) Always special designed and tailor made;
2) Welding fixture and supporting equipment do not work with individually, but instead, always work as assistant units for Welding Equipment, and or Pipe Welding Machine, etc.

Welding Fixture and Welding Supporting Equipment Designed and Produced by Wuxi JACK

Welding Fixture

1. Usage and Application of Welding Fixture:

1) Welding Fixture is for positioning and fixing workpieces during manual and or automatic welding, so that welding can be performed in the most reasonable and comfortable position for operator, and eligible welding quality can be got accordingly;
2) In this respect, welding fixture has similar and overlapping function with Welding Positioner. The difference between welding fixture and Welding Positioner lies in: Due to the structure of workpiece, welding fixture has more complicated design than Welding Positioner in terms of securing workpieces;
3) Welding Fixture sees majority application in batch production, applied in various types of production lines, in Vehicle Industry, Engineering Machinery, Automobile Industry, etc.


2. Technical Characteristics of Welding Fixture:

1) Welding Fixture holds and clamps workpieces by means of fixed or revolving work table, and numerous pliers as its clamping points along the whole length of workpiece;
2) Majority of the pliers in Welding Fixture are manipulated manually by hand. Sometimes, air cylinders are used in Welding Fixture, for getting heavier clamping force, as well as quicker clamping operation in Welding Fixture;
3) Welding Fixture differs case by case. The design of Welding Fixture is based on design of workpieces, with the introduction of VPA (Virtual Production Analysis, 3D Simulation) in the process;
4) The manufacture of Welding Fixture should be validated by means of CMM (Coordinate Measurement Machine). The positioning of Welding Fixture can be maintained within the tolerance of ±1mm;
5) Another requirement on Welding Fixture is its durability: Maintain the accuracy and precision of Welding Fixture after long time use, which should be tested periodically by professional team.

Hobbing Cutter

1. Outline on the Purpose and Application of Hobbing Cutter:

1) Hobbing Cutter, the other name is Rolling Shear Beveling Machine, is for making welding groove on small to medium thickness metal plate, by means of the high speed revolution of cutter blade;
2) So, Hobbing Cutter has similar function as Edge Milling Machine and Flame Triple Cutting Machine;
3) This Rolling Shear Beveling Machine has capability of making beveling in the angular range of 25°~ 45°, on materials of carbon steel/ 16Mn, etc. Depending on tensile strength of workpiece material, the max. thickness that can be processed in this Rolling Shear Beveling Machine is up to 20mm.



2. Strong Points of Rolling Shear Beveling Machine:

1) As can be seen from its photos, this product of Hobbing Cutter has compact size and simple structure. Correspondingly, its operation and maintenance are easy and simple;

2) Besides, compared with Edge Milling Machine and Triple Flame Cutitng Machine, the other advantage of Rolling Shear Beveling Machine is its lower purchase cost, and lower running cost;
3) Beveling speed in Hobbing Cutter is fairly high (Around 3000 mm/min.), and the cutting kerf on metal plate after machined in Hobbing Cutter does not need trimming off slag.



3. Model and Technical Parameters of GD Series Rolling Shear Beveling Machine:

There is one standard model of GD20 Hobbing Cutter:
 Model of Rolling Shear Beveling
 Plate Tension Stress δb (N/mm2)  <400/ >400~500/ 
  Plate Material  Q235/ Q345/ 1Cr18Ni9TiQ
  Bevel Width W  20 mm/ 16 mm / 12 mm
  Small Plate Chamfering Speed   2900 / 3100/ 3400 mm/min.
  Plate Max. thickness h   40 mm
  Bevel Angle Range α   25° ~ 55°
 Min. Blunt Size e   2 mm
  Dimension (L x W x H)  1240 x 940 x 1500 mm
 Motor model Y112M-4  4KW/ 1440 rpm
 Main Shaft Revolving Speed  7.7 rpm
 Diameter of Milling Tool  φ200 mm

Working Principle and Operation of Hobbing Cutter

1. How does Rolling Shear Beveling Machine make Grooves on Metal Plate?

The 1st Photo taken on lateral view of the Hobbing Cutter gives the theory of running way in this Rolling Shear Beveling Machine:
1) There is piece of revolving cutter in the upper section of the Hobbing Cutter main frame, which is driven with A.C. motor;
2) Beneath the cutter head, there is a piece of solid running roller, for supporting and conveying metal plate forward;
3) With traveling of the metal plate through the main frame of the Hobbing Cutter, edge of the metal plate got sheared and beveled;
4) Outside the main frame of the Rolling Shear Beveling Machine,the bottom handwheel is for raising up supporting roller of the metal plate, based on its thickness; And the 2 pieces of upper handwheels are for holding down the metal plate, during working of the Rolling Shear Beveling Machine.

2. How to Operate the Rolling Shear Beveling Machine?

The 2nd photo gives overall view of the Rolling Shear Beveling Machine, as well as how to operate it:
1) Control board and buttons/ switches are installed on lateral side of Hobbing Cutter main frame, together with foot pedal switch for sending in of the metal plate;
2) There is angle scale assembled onto wall board, indicating and controlling beveled angle of metal plate delivered from the Rolling Shear Beveling Machine;
3) Suppose the metal plate to be machined in the Hobbing Cutter has broad width. Then, as shown in the 3rd photo, workpiece supporting racks can be equipped with the Hobbing Cutter;
4) The 4th photo gives beveled metal plate from GD20 Rolling Shear Beveling Machine.

Heavy duty Edge Milling Machine

1. The Function and Working Principle of Heavy duty Edge Milling Machine:

1) Here the description of “Heavy duty” is on the basis of comparison with XBJ/ SXBJ series Edge Milling Machine: Mainly referring to the aspect of edge milling efficiency;
2) Working principle of Heavy duty Edge Milling Machine is illustrated below:

 Fig Edge Milling Machine 14

3) As can be seen from above, in this kind of heavy duty Edge Milling Machine, the metal plate travels through the machine in high edge milling speed (3000~ 5000 mm/min.), which is 4~5 times that of the XBJ/ SXBJ series Edge Milling Machine;
4) Besides, with both sides installed with 55kW milling head in the main body of heavy duty Edge Milling Machine, compared with 7.5/9.5kW milling head in XBJ/ SXBJ series, both sides of metal plate can be edge milled with one time stroke in this Heavy duty Edge Milling Machine.


2. Technical Parameters of Heavy duty Edge Milling Machine:

 Max. Edge Milling Length (mm)  No restriction
 Power of Milling Head  55kW x 2
  Plate Thickness  12∼50 mm
  Edge Milling Speed  3000∼5000mm/min.
(VFD, Inverter Control)
  Idle Speed   5000 mm/min.

Portable Special Welding Positioner

1. The Application of Special Welding Positioner:

1) This is a set of special design and produced Special Welding Positioner, applied in precision welding of precision workpiece: Plasma welding and or electron beam welding, on strictly controlled mandrel rod;
2) Judging on its task, this Special Welding Positioner can be either attributed as Welding Fixture, or Welding Positioner.



2. The Technical Features of Special Welding Positioner:

1) Although with compact size, to get precise and extensive range of workpiece revolution, this Special Welding Positioner is equipped with servo motor for its revolving action;
2) Based on length of mandrel rod, the 3-claw chuck for clamping workpiece can be moved along the entire length of Special Welding Positioner base bed, which is manipulated with handwheel, and guided with high precision linear guiderail.



3. Technical Parameters of Special Welding Positioner:

 Workpiece Diameter Scope  6 ~ 150 mm
 Workpiece Thickness  ≦ 1 mm
 6mm Dia. Workpiece Revolution
 50 ~100mm/min.
  150mm Dia. Workpiece Revolution
  Workpiece Revolution Speed Range  0.12 ~ 6 rpm.

Rolling Boring Machine

1. Function and Application Site of Rolling Boring Machine:

1) Rolling Boring Machine is for the purpose of machining internal surface of hollow cylinder body or tubes, in the form of forward rolling and backward boring of machine tool. It is an indispensable equipment in Cylinder Facilities;
2) During work of the Rolling Boring Machine, the workpiece is clamped onto a fixture. The machining tool is installed opposing it, with the spindle in the same circle center as the workpiece;
3) By means of the high speed revolution of spindle, the machining tool is first sent in, then retreated out of the internal hole of workpiece.



2. Technical Parameters of Rolling Boring Machine:

 Rectify Roundness of the Cylinder
 Deep Hole
 Ellipticity ≤0.01mm
 Surface Hardness  HV ≥ 4°
 Roughness Degree  Ra < 0.2
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