1. Welding Fixture and Welding Groove Processing Machine:

Although directly carry out welding operation, these equipment play critical role in guaranteeing welding performance:
1) Hobbing Cutter (Rolling Shear Chamfering Machine), cutting welding grooves on small metal plates;
2) Conventional single or double heads Edge Milling Machine, cutting welding grooves on medium to large sized steel plates;
3) Plate moving style heavy duty Large Edge Milling Machine, cutting welding grooves on very large steel plates;
4) Small Welding Positioner, supporting on tailor made high precision welding;
5) Rolling Boring Machine, machining on cylindrical workpieces;
All serve important role on various welding operations in industry.

2. Importance of Welding Fixture and Welding Groove Processing Machine:

Function: These Welding Fixture and auxiliary equipment, although not directly involved in welding operation, play key role in welding operation prepare and process assistance, helping guaranteeing high level and stable welding performance:
1) Cut out welding groove on steel plate: Machining with straight or slant bevel on edges of sheet metal plate:
a) Cut out welding groove on small plate with Hobbing Cutter;
b) Cut out welding groove on large plate by means of heavy duty large Edge Milling Machine;
c) Rolling Boring Machine on cylindrical workpieces;
2) Welding Fixture: Clamp various complicated workpieces securely into different welding equipment, need special design and tailor made;
3) Special Small Welding Positioner: Help secure small workpiece for high precision welding, and make its orientation most applicable for delicate welding.
 

3. Technical Common Points of Welding Fixture and Welding Groove Processing Machine:

1) Special design: The lead time and manufacturing cost will be accordingly higher, and lots of communication involved during business negotiation between customer and supplier;
2) Work together with Other Welding Equipment: Welding fixture and support equipment do not operate individually. Instead, often work as supplementary units for various Welding Equipment, such as Pipe Welding Machine, etc.

1. Indispensable Role and Extensive Use of Welding Fixture:

1) Workpiece Clamp and Positioning: Welding Fixture is for positioning and firmly fixing workpieces during manual or automatic welding operation, especially complicated structure workpieces;
2) Function and Benefit: This is for acquiring the most reasonable and comfortable welding position for operator and welding machinery, as well as producing the best welding quality accordingly;

3) Related Equipment with Welding Fixture:

a) In this sense, welding fixture has similar and overlapping function with Welding Positioner: Application of welding positioner can not be separated from welding fixture, the latter is usually applied in welding turntable of different types of welding positioner, help maintaining workpiece revolve, tilt, and elevation;
b) When Welding Positioner changes position and orientation of workpiece by means of rotation/ tilt/ elevation, workpiece need to be secured firmly and reliably in the process, by means of various designed welding fixture. In this respect, these 2 types of welding assist equipment always work in pairs;
c) The difference between Welding Fixture and Welding Positioner: Considering the varied structure of workpieces, welding fixture has more complicated and different design than Welding Positioner, for purpose of reliably securing workpieces. Besides, welding fixture itself do not have power. It is a kind of tool, instead of equipment;

4) Application of Welding Fixture:

Welding Fixture is usually special designed and produced, which has relatively higher manufacturing cost and longer lead time. The customer accepts such higher cost in financial and time usually come from industries with batch production:
a) Steel Structure construction;
b) Manufacture on various vehicle bodies;
c) Rail transit manufacture;
d) Bicycle and motorcycle manufacture;
e) Engineering and construction engineering;
f) Frame and box manufacture;
g) Pressure vessel;
h) Robot welding;
i) 1st operation- Sheet metal processing;
j) Metal furniture;
k) Equipment assembly;
l) Fabrication and inspection on industrial pipeline (Flange)...
 

2. Technical Characteristics of Welding Fixture:

1) Work Table and Pliers: Welding Fixture holds and clamps steel structure workpieces by means of fixed or revolving work table. Numerous pliers are used as clamping points along the entire length of welding table, workpiece and Welding Fixture itself;
2) Way of Clamp: Majority of the pliers in Welding Fixture are manipulated manually by operator. Sometimes, air cylinders are used in Welding Fixture, for getting heavier clamping force, as well as quicker clamping operation, when workpieces have large dimension and heavier weight;
3) Special Design and Validation: Welding Fixture differs case by case. The design of Welding Fixture is based on workpiece specifications. The design process is usually validated with VPA (Virtual Production Analysis, 3D Simulation) in the procedure;
4) Production Validation and Precision: The manufacture of Welding Fixture should be validated by means of CMM (Coordinate Measurement Machine) to test on its accurate dimension. The positioning precision of Welding Fixture can be maintained within the tolerance of ±1mm;
5) Stability and Durability: Another requirement on Welding Fixture is its stability and durability: Maintain the accuracy and precision of Welding Fixture unchanged after long time use, which should be tested periodically by professional team. This is because correct position and secure on workpiece, which directly affects on subsequent welding quality, is guaranteed with durability and precision of Welding Fixture.

1. Function and Application of Rolling Shear Chamfering Machine:

1) Task and Workpiece: Hobbing Cutter, the other name is Rolling Shear Chamfering Machine, is for cut out welding groove on small to medium thickness small metal plate, especially steel plate, in high efficiency, by means of the high speed revolution of cutter blade in its cavity;
2) Work principle of the equipment is by means of high revolutionary revolved cutter head, hence the equipment name get from; It is a kind of niche product in market, which means, not much supplier produce this equipment, but this equipment has very versatile application;
3) Related Equipment with Similar Function: In terms of cut out straight and slant edge groove, this equipment has similar function as Edge Milling Machine and CNC Flame Triple Cutting Machine;

2. Advantage of Hobbing Cutter (Rolling Shear Chamfering Machine):

As can be seen from the righthand photos, compared with the much larger and more expensive Edge Milling Machine and CNC Flame Triple Cutting Machine, this equipment has strong points of:
1) Compact size, occupies very small space in workshop, and easy for planning on layout in production line;
2) Integral simple structure: Correspondingly, its transportation, fixation, operation start up and maintenance are easy and simple;
3) Cost effectiveness: Much lower manufacturing cost and hence selling price; The daily operation cost on the machine is also obviously lower;
4) High efficiency: Not only beveling itself has high speed, but also plate loading on and off takes short time;

3. Technical Capability of Hobbing Cutter (Rolling Shear Chamfering Machine):

Machining beveling on sheet metal:
1) Bevel Angle: In the angular scope of 25°~ 45°;
2) Material: On materials of carbon steel (Q235, Q345)/ 16Mn, etc.;
3) Plate Thickness: Depending on tensile strength of sheet metal material, the max. thickness that can be processed in this GD20 model machine is up to 20mm;
4) Edge beveling Speed: Also depending on tensile strength of sheet metal material, from 2,900mm/min. up to 3,400mm/min.;

4. Technical Strong Points of Hobbing Cutter (Rolling Shear Chamfering Machine):

1) Safe Operation: The rolling shear is assembled deep inside cutting cavity. It is hard for operator to get access on rolling shear in revolution, and hence avoid safety hazard of hands get entangled and squeezed during operation;
2) Convenient Work: There are handwheels at different positions of equipment section, for making adjustment on different units separately. Together with foot pedal switch, operator can manage on beveling on sheet metal in high efficiency;
3) Design of mechanical structure has ingenious idea, which, although compact, is rather complicated and sophisticated, while being applied for close to 20 years from 2009 until today in beginning of year 2026, with very stable and reliable performance;

4) Daily Low Running Cost of Rolling Shear Chamfering Machine:

a) The electric power consumption is low;
b) No hydraulic and pneumatic involved in the machine;
c) Besides rolling shear, which is rather durable so long as operated and maintained properly, no other consumables involved in the operation;
d) No need 2nd time trimming on cut welding groove on edge of small plate;
5) Material of sheet metal is not confined to carbon steel. Instead, this Rolling Shear Chamfering Machine can also work on high strength and non-ferrous metal such as 1Cr18Ni9TiQ, which greatly extends equipment application scope;
6) High Efficiency and Gloss Bevel: Beveling speed in Hobbing Cutter is fairly high: Around 3,000 mm/min.); The finished cutting kerf on metal plate after machining from this machine does not need to be trimmed off slag.
 

5. Model and Technical Parameters of Hobbing Cutter (Rolling Shear Chamfering Machine):

Below is standard model of Wuxi JACK GD20 model machine technical specifications:

1. Function and Advantages of Plate Moving Type Large Edge Milling Machine:

1) Function: Cut out beveling on double edges of steel plate in high speed, forming V/ Y/X and other types of welding groove. So, it serves as welding assistant equipment for large projects;
2) Strong Points: Here “Heavy duty” refers to comparison with conventional XBJ and SXBJ models Edge Milling Machine: Implicating on high edge milling efficiency: Compared with 100~ 1000mm/min. in conventional Edge Milling Machine，this heavy duty machine can deliver 3000~ 5000mm/min. edge milling velocity;

2. Work Principle of Plate Moving Type Heavy duty Edge Milling Machine:

1) Operating form of this large Welding Groove Processing Machine is illustrated below: (Fig.2)

2) Structure of Large Edge Milling Machine: There are 2 sets of high power 55kW milling heads being installed at both sides of the steel plate. When the sheet metal plate moves through the heavy duty large machine in working speed, both lateral sides of plate are being edge milled into finished groove;
3) Work Way: This means, steel plate moves in high working speed, compared with stationary plate in conventional Edge Milling Machine;
4) Edge Milling Speed: 3,000~ 5,000 mm/min., which is 4 to 5 times that of conventional XBJ and SXBJ series Edge Milling Machine;
5) Milling Head Power: 55kW milling head in the mechanical main body of heavy duty Edge Milling Machine, compared with 7.5kW or 9.3kW power milling head in XBJ and SXBJ series conventional machine;
6) High Efficient Edge Milling: Both sides of sheet metal plate can be edge milled with one time stroke in this heavy duty machine.
 

3. Technical Parameters of Plate Moving Type Heavy duty Large Edge Milling Machine:

1. Task and Application of Special Made Small Welding Positioner:

1) Background: This small welding equipment was developed and produced for a Chinese top level 985 project university, for their welding technology department. The most conspicuous feature is its high precision welding, there is strict regulation on welding precision tolerance in the contract;
2) Applicable Workpiece and Welding Form: This is a set of special design and produced “Tiny” Welding Positioner, being applied in precision welding on very small workpiece: Plasma welding and or electron beam welding, on strictly controlled mandrel rod;
3) Specialty: Although with small size, this Welding Fixture has high precision and delicate craftsmanship. Its mandrel is finely machined, and movement of positioner is guided with high precision linear guiderail;
4) Work Nature: It is a delicate design and produced welding equipment. Judging on its function, this special made tiny Welding Positioner works as supporting Welding Fixture, to fulfil special welding jobs on special workpieces. The welding precision tolerance is highly managed.
 

2. Technical Features of Special Made Small Welding Positioner:

1) Servo Motor Drive for Workpiece Revolve: As compact size Welding Fixture which works on small workpieces, to acquire precise welding performance on extensive range of workpiece revolution, this special made small Welding Positioner is equipped with servo motor for its faceplate revolving action;
2) Operating Style: Based on length of mandrel rod, the 3 claws chuck for clamping workpiece can be moved along the entire length of the special made small Welding Positioner base bed. The revolve for welding is manipulated with handwheel, and guided with high precision linear guiderail.
 

3. Technical Parameters of Special Made Small Welding Positioner:

1. Function and Application Site of Rolling Boring Machine:

1) Applicable Workpieces: 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 Welding Groove Processing Machine in Cylinder Facilities;
2) Operating Form: During operation, the cylindrical workpiece is clamped into a Welding Fixture. The machining tool is installed opposing the Welding Fixture, with the spindle in the same circle center as the cylindrical workpiece;
3) Performance: 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 in the machine.
 

2. Technical Parameters of Rolling Boring Machine: