Land leveler blade is the core vulnerable component for earthwork operations, directly facing high impact and severe wear conditions. Therefore, its production process needs to simultaneously address the contradiction between hardness (wear resistance) and toughness (impact resistance). The following is the entire production and manufacturing process based on existing patented technology and industrial practice:
Production and manufacturing process of flatbed blade
Step 1: Ingredients and Smelting
- Material selection: Select alloy steel with specific chemical composition according to the performance requirements of the grader blade. Common materials include 65Mn (manganese steel), 30MnB (boron steel), or proprietary high wear in steel
- Chemical composition control: In order to improve the service life of the blade of the grader, modern technology will precisely control the proportion of elements. For example, a formula for a highly durable sharpening blade includes: C (carbon) 0.25-0.27% to ensure hardness, Mn (manganese) 0.8-1% to enhance toughness, and the addition of wear-resistant elements such as W (tungsten) 1.5-2% and Si-B-C-N nanocrystalline amorphous particles
- Smelting and refining: Smelting is carried out in an electric furnace, and harmful gases and impurities in the molten steel are removed through desulfurization, dephosphorization, and vacuum degassing treatment to improve the purity and density of the steel.
Step 2: Forming
- Casting or rolling:
- Casting method: Pour molten steel into a die-casting mold and slowly cool it under pressure to form. This method can make the material structure dense, avoiding the formation of looseness and bubbles.
- Section steel rolling method: For specific shapes (such as curved plates), the curvature and groove of the blade are directly rolled from the profile, which can save the subsequent complex planing process and reduce costs.
- Punching: When the material has not completely cooled to room temperature (hot state), use hot stamping equipment to punch the blade mounting hole in one go. Hot stamping can reduce internal stress and prevent cracking compared to cold stamping.
Step 3: Heat treatment
Heat treatment is the core process that determines the performance of blades, mainly using the following techniques:
- Process Plan A: Overall Quenching+Hot Pressing Forming
- Purpose: To solve the problem of “sickle shaped” bending deformation caused by asymmetric structure of blades.
- Process: Heat the blade to 800~820 ℃ and quickly place it into a specially designed quenching mold. Apply a pressure of 200-400 tons through a pressure machine, and inject quenching solution at 20-60 ℃ for rapid cooling while compressing. This “pressing and quenching” method can forcibly correct deformation while increasing hardness.
- Process Plan B: Pre deformed medium frequency quenching
- Purpose: To use thermal stress to counteract the deformation caused by quenching.
- Process: First, continuously heat and cool the opposite edge of the blade edge to obtain a pre deformation, and then perform surface quenching on the working edge.
- Process Plan C: High Wear Resistant Injection Infiltration Process
- Process: Place the blade into a vacuum furnace, use high-energy pulse current to impact the tungsten target, allowing tungsten ions to penetrate the surface of the blade (ion implantation), and then perform carburizing and quenching. This can form an extremely hard tungsten carbide layer on the surface, with a surface hardness of HRC 56-60.
Step 4: Tempering
- Process: After quenching, there is significant brittleness inside the blade. The blade needs to be placed in a tempering furnace, heated to 280-430 ℃, held for 90-120 minutes, and then taken out for air cooling.
- Function: Eliminate quenching stress, adjust the matching of hardness and toughness, and prevent brittle fracture of the blade during operation.
Step 5: Precision machining and inspection
- Surface treatment: Polish the working surface of the blade to remove the oxide film generated during the heat treatment process.
- quality testing:
- Hardness testing: Check whether the surface hardness of the blade meets the design requirements (usually between HRC 40-55 or even higher).
- Ultrasonic testing: Check for the presence of microcracks or pores inside.
- Dimensional inspection: Use measuring tools to check the straightness of the blade and the positional accuracy of the mounting hole.
Step 6: Surface Identification and Packaging
- Marking: Print specifications, materials, production batch numbers, and other information on the non working surface of the blade.
- Rust prevention and storage: Apply rust prevention oil, package and store for sale.
summary
The manufacturing of grader blades is a combination of materials science and precision machining. Modern blade production is no longer just about “forging+grinding”, but through “component fine-tuning+thermo mechanical coupling treatment” (such as overall quenching and pressure shaping or ion implantation) to maximize the service life of blades under harsh working conditions.
Welcome to contact our sales engineer Mr. Li Chao for consultation. Our products are applied to other models of graders such as Caterpillar, Komatsu, Mitsubishi Heavy Industries, XCMG, and Sany Heavy Industries. We can also customize non-standard size grader blades for you
