Customized processing of cast iron ground rails

Customized processing of cast iron ground rails

The ground rail, also known as T-shaped groove ground rail, ground beam, groove iron, foundation groove iron, cast iron ground rail, and strip platform.

The purpose of the ground rail is to design and assemble a casting beam platform based on the fixed points of the equipment, mainly used for the assembly, testing, welding, and inspection of large equipment.

T-shaped groove ground rails are used for assembly, testing, welding, and inspection of large equipment.

The material of the T-shaped groove ground rail is cast iron HT200-300.

The specifications of T-shaped groove ground rails can be determined according to the area laid by the customer.

The installation of T-shaped groove ground rails is fixed and adjusted using anchor bolts and top screws.

The T-shaped groove ground rail is designed and assembled into a casting beam platform based on the fixed points of the equipment, and is used for assembly, implementation, welding, and inspection of large equipment.

The material of the T-shaped groove ground rail is cast iron HT200-300, with a mandatory surface hardness of HB170-240. After two manual treatments (manual annealing at 600-700 degrees and natural aging for 2-3 years), the accuracy of the product remains unchanged, and its function is good.

Specification of T-shaped groove ground rail: Specific specifications can be manufactured according to the buyer's drawings or agreed upon by both parties for production and processing

Cast iron ground railPrecautions for use:

1、 Installation and fixing precautions

Basic processing

Ground requirements: The installation ground should be flat, solid, and free of vibration sources (such as punching machines, air compressors, etc.). If the ground is uneven, it is necessary to adjust the pad iron or epoxy resin mortar to level it, ensuring that the bottom surface of the ground rail contacts the ground evenly and avoiding deformation caused by local suspension.

Fixed method:

Use M12-M16 anchor bolts or chemical anchor bolts for fixation, with a recommended bolt spacing of 500-800mm, to ensure that the ground rail does not shift under load.

For heavy-duty ground rails (carrying>5 tons), steel plates need to be pre embedded in the foundation to enhance stability through welding or bolt connections.

Horizontal adjustment

Initial adjustment: Use a laser level or frame level for rough adjustment to ensure that the longitudinal and transverse levelness deviation of the ground rail is ≤ 0.2mm/m.

Fine tuning: By adjusting the shims or anchor bolts and coordinating with the image level, the final horizontal deviation should be ≤ 0.05mm/m (high-precision scenario).

Parallelism calibration: When multiple ground rails are used in combination, a dial gauge should be used to check the parallelism of adjacent ground rails, with a deviation of ≤ 0.1mm/m.

2、 Precautions during use

Load control

Uniform distribution: Workpieces or equipment should be evenly placed on the ground rail to avoid local overloading (such as single point bearing>50% of the rated load of the ground rail).

Dynamic load limitation: If the ground rail is used for mobile equipment (such as robot slides), dynamic loads (such as impact force and inertia force) need to be calculated to ensure that the total load does not exceed 70% of the rated value.

Overload warning: It is strictly prohibited to stack heavy objects on the ground rail or use it as a fulcrum for lifting equipment to prevent structural deformation.

Temperature and humidity management

Environmental temperature: It is recommended to control the working temperature of the ground rail at 10-40 ℃ to avoid thermal expansion and contraction deformation caused by temperature differences (such as entering high-temperature workshops directly after outdoor use in winter).

Humidity control: The relative humidity should be ≤ 70% to prevent cast iron from absorbing moisture and rusting. If the environment is humid, it is necessary to regularly apply rust proof oil or use dehumidification equipment.

Cleaning and Anti fouling

Daily cleaning: Use a soft bristled brush or vacuum cleaner to remove dust and iron filings from the surface of the track, avoiding scratches on the work surface by hard objects.

Oil pollution treatment: If the ground rail is contaminated with cutting fluid or lubricating oil, it should be wiped with a neutral cleaning agent. The use of corrosive solvents such as gasoline and acetone is prohibited.

Rust prevention measures: When not in use for a long time, apply rust proof oil (such as Vaseline or special rust proof grease) and cover with a dust cover.

3、 Key points of maintenance and upkeep

Regular verification

Precision re inspection: Every 6-12 months, use a laser interferometer or electronic level to test the flatness and straightness of the ground rail. If the deviation exceeds the allowable value (such as flatness>0.1mm/m), it needs to be returned to the factory for scraping and repair.

Functional testing: Check if the T-shaped groove and bolt holes are worn. If the gap is greater than 0.2mm, replace the locating pin or bolt.

Repair and Renovation

Local damage repair: If there are scratches or rust on the working surface, it can be polished with oilstone or sandpaper (mesh size ≥ 800 #), and then coated with anti rust oil.

Overall renovation: When used for more than 5 years or when the accuracy significantly decreases, it is necessary to return to the factory for scraping and quenching treatment to restore surface hardness (HRC ≥ 180) and contact point density (≥ 20 points/cm ²).

Lubrication management

T-groove lubrication: Regularly (every 3 months) apply lubricating grease (such as lithium molybdenum disulfide grease) to the T-groove to reduce the sliding resistance of bolts and pressure plates.

Guide rail surface protection: It is prohibited to directly spray lubricating oil on the working surface of the ground rail to prevent the adsorption of dust and the formation of abrasive wear.

4、 Safety operation standards

Personal protection

Operators are required to wear safety helmets and anti smashing shoes to prevent heavy objects from falling and injuring people.

When using electric tools such as angle grinders, it is necessary to wear goggles and dust masks.

Equipment safety

Protective barriers or warning signs should be set up around the track to prevent unrelated personnel from touching it.

When moving heavy workpieces, it is necessary to use a crane or forklift, and manual dragging is prohibited to cause the ground rail to overturn.

Emergency response

If there is abnormal vibration or noise in the ground rail, the machine should be stopped immediately for inspection to eliminate problems such as loose bolts and foundation settlement.

When a fire occurs, it is forbidden to use water to extinguish it (cast iron is prone to cracking when exposed to rapid cooling), and dry powder fire extinguishers should be used instead.