45 Steel Supplier | C45, S45C, 1045, Machining Service

C45

Chemical Composition

Steelmaking furnace temperature burns to 1600°C, molten iron rolls and boils. Workers closely stare at temperature measuring thermocouple, 0.42% to 0.50% of carbon atoms penetrate into molten steel interior. Carbon mass fraction stops at around 0.45%, iron element and carbon element combine into a hard substance called cementite (Fe3C).

Carbon content breaks through 0.50% boundary, lathe tool cutting resistance multiplies increases, blade wear is extremely fast. Carbon content drops to below 0.42%, when factory masters use water to cool and quench, the reading on Rockwell hardness tester is very hard to stably exceed HRC45 red line.

Manganese element's addition amount is strictly stuck in 0.50% to 0.80% interval.

· Cooling speed data is forcibly pulled down 15%

· Crystal transformation's time point backward greatly shifts

· Furnace inside deoxidation residual amount is dead pressed at below 0.05%

· Prevent low melting point iron sulfide crystal nucleus massive generation

Silicon element's highest scale line is drawn at 0.40% position. Treat as deoxidation process's residual to look, 0.15% to 0.30% silicon proportion can pull high matrix yield strength 30 MPa.

Silicon content exceeding standard will provoke big trouble, under 1200°C high temperature forging will generate massive silicate impurities, destroy metal internal original coherent fiber texture. Laboratory inside's spark spectrometer 24 hours stares at silicon element's wave peak jumping.

Phosphorus content's highest limit is nailed dead at 0.030%. On assay documents even if only extra out 0.005%, extreme cold environment inside's steel material receiving impact fracture's probability will multiply enlarge.

Sulfur and iron bumping together will become melting point only 985°C's iron sulfide. Steel ingot pushed into 1100°C heating furnace preparing hot rolling, inside melted liquid film will let the whole piece of steel material along crystal edge instantly tear open.

· Phosphorus element easily gathers into fragile segregation band

· Cold environment under's fracture source mostly comes from rich phosphorus zone

· Sulfur element's mass red line absolutely cannot exceed 0.035%

· 1200°C hot processing time steel block becomes brittle cracking all blame sulfur element

Toward molten steel inside add manganese can manage sulfur, the two bumping heads become high temperature resistant manganese sulfide. Bumping into requirement extremely high forging order, outside furnace refining equipment will start vacuum degassing function, forcibly pump low sulfur content to within 0.015%.

Waste old steel iron returning to furnace brought in chromium, nickel, copper, highest content red line absolutely cannot cross over 0.25%. Nickel content running to 0.30%, heat treatment workshop's hardness tester will frequently report error, old water cooling formula on the spot loses effect.

· Return furnace waste steel brought in copper content dead knocks 0.25% upper limit

· Copper element meeting high temperature easily lets surface layer appear network cracking lines

· Chromium residual passing 0.20% will let cutting processing very strenuous

· Hydrogen gas etc gas elements must be extracted away to below 2ppm

· Mixed in trace vanadium titanium will let hardness uncontrolledly randomly jump

Steelmaking blown in nitrogen gas in molten iron inside's solubility drops from 0.04% to 0.004%. Not run out nitrogen gas wanders in crystal lattice gaps inside, room temperature placed for several months then becomes hard, taken to punching machine on one press edge on the spot cracks.

Aluminum powder according to 0.015% to 0.050% fixed ratio weighed scattered in. 10 to 50 nanometer size's aluminum nitride particles run out stuck crystal boundary. ASTM E112 grain size rating stabilizes at 5 grade to 8 grade, 50 ton testing machine pulled broken test bar cross section shrinkage rate approaches 45%.

Use 4% nitric acid alcohol to corrode test block, microscope magnifies 500 times to see, white color ferrite Vickers hardness only has 80HV, black color pearlite hardness rushes to 250HV. 0.45% carbon content lets two kinds of substances each occupy 50% volume proportion, soft hard material ratio exactly half to half.

Mechanical Properties & Heat Treatment

Steel factory out warehouse's C45 round steel mostly locates in normalized state. Annealing furnace's temperature is set at 840°C to 860°C, workpiece in furnace chamber inside keeps warm two hours after being dragged out thrown on empty ground naturally cools. Internal crystal grains in air inside rearrange, tensile testing machine on's pointer steadily stops at 600 MPa's tensile strength scale line.

Inspector holding Brinell hardness tester on surface hits down a concave pit, reading normally falls in 160 to 210HB interval. This state's steel material exactly can let lathe's alloy blade smoothly cut in, per minute 150 revolutions' spindle rotating speed under, silver white iron chips along blade tip break into neat spiral shape. Yield strength stays at 340 MPa, making some common bearing seats is enough.

To deal with heavy load working conditions, workshop must start quenching and tempering heating furnace. Instrument panel numbers jump to 820°C to 840°C, workpiece according to effective thickness per millimeter 1.5 minutes' coefficient calculates warm keeping time length. Burned completely red steel material is hoisted by overhead crane, emitting hot gas hangs above quenching liquid tank waiting to enter water.

0.45%'s carbon content lets cooling medium's choice become like walking on thin ice. Pure water cooling's temperature dropping speed as high as per second 600°C, internal structure expansion generated huge pulling force very easily can tear out naked eye visible cracks on parts on the spot. Experienced masters will heat water temperature to 30°C around, or change into temperature dropping speed only per second 150°C's dedicated quenching oil.

Quenching out tank's parts placed under hardness tester to test, Rockwell hardness soars to HRC55 up and down. Located in full martensite state's steel block is as brittle as glass, from one meter high workbench dropping on cement ground all will chip off a piece of corner. Within a few hours workers must push it into tempering furnace, reset parameters to conduct secondary baking.

· 550°C high temperature tempering two hours, yield strength stabilizes at 490 MPa above.

· 200°C low temperature tempering eliminates internal stress, surface retains HRC50's hardness value.

· Medium temperature 400°C tempering treatment after, elastic limit value doubled one time.

· Workpiece cross section diameter exceeds 50 millimeters, center area extremely difficult to completely quench through.

High temperature tempering out's structure is called tempered sorbite, it can resist heavy machinery tens of thousands of times of repeated impact without fracturing. If drawing requires gear surface wear-resistant, master will move out surface induction heating coil. 200 kilowatts' AC current flows through for a few seconds, gear surface two three millimeters' depth instantly burns red.

High pressure spray head immediately sprays water rapid cooling, tooth surface hardness flees to between HRC45 to 52. Use file on top forcefully scratch pass, even a single white mark cannot be left behind. Gear interior still maintains 200HB around's soft cooked state, meeting sudden heavy pressure impact only will deform a little bit, absolutely will not whole piece shatter crack.

Tensile, impact, hardness these mechanical data are recorded on leaving factory assay sheet. Use a table to list out different states under's test results to compare more intuitively. Table inside's values correspond to cross section area less than 25 millimeters' standard test bar actual test results, thickness once increases, center zone's hardness data will present step shape drop down.

Thickness 100 millimeters' round steel water quenched after split open, take hardness tester from outer ring towards circle center every interval 5 millimeters hit a point. Surface layer hardness still can barely support at HRC45, walking inward 20 millimeters reading then drops to HRC30. Arrived at circle center position, pointer even HRC20 cannot point to, completely is a ball of soft pearlite.

Operators think of all ways to destroy steel material surface that layer of heat dissipation hindering vapor film. Various formulas' quenching liquids forcibly pull high 650°C to 550°C high temperature zone's temperature dropping speed, hundreds of liters liquid under circulation pump's agitation rolls over, hot workpiece smashed in emits a burst of muffled hissing sound. Workshop inside normally prepares four kinds of cooling liquids to deal with different sizes' rough blanks:

· 5% to 10%'s sodium chloride salt water, specially treats 60 millimeters above difficult to quench through thick shafts.

· 8% to 15%'s PAG water solvent, specially used to soak shape complex eccentric wheels.

· 30°C around's fast quenching oil, serves easy to deform crack thin wall parts.

· Temperature dropping speed per second 600°C's pure tap water, only dare to be used to process big headed waste steel.

Out tank after use temperature measuring gun sweep pass, part surface temperature stops at 150°C to 200°C. Worker wearing asbestos gloves grabs up workpiece, taking advantage of hot throws into already preheated good tempering furnace. This with temperature tempering's operation action is extremely fast, deeply fearing that 0.45% carbon content generated phase transformation internal stress after thoroughly completely cooling down will pull crack the part.

Fatigue testing machine on's eccentric wheel 24 hours rotates non-stop, per minute applies 3000 times alternating load. Passed through standard quenching and tempering process treated test bar survived 10 to the 7th power times cycle still without fracture's sign. Fatigue limit strength stops at 275 MPa nearby, machine spindle all year round running totally depends on this data indicator supporting.

Furnace temperature instrument panel if set deviated 50°C, mechanical inspection paper on's numbers will change beyond recognition. 500°C tempering's tensile strength can rush to 850 MPa, arrived at 600°C then only left 700 MPa a little bit over. Inspection department's tensile machine one pull, elongation rate's data jumps from 14% to 20%, drawing requirement slightly stricter a bit the whole batch of goods then has to rework re-burn.

S45C

Global Equivalent Grades

Drawing prints Japanese standard S45C, steel factory delivery list often writes European standard C45 or American standard 1045. Everyone usually treats them as the same one kind of material to use, lathe master processing time, trace elements' tiny differences will bring completely different hand feel. American standard 1045's carbon content is between 0.43% to 0.50%, Japanese standard S45C is stuck at 0.42% to 0.48%. Difference this 0.02%'s carbon, put into 850°C's fire furnace inside burn red quench, steel material internally formed hardened structure proportion is completely not the same.

Steelmaking factory used waste iron and iron ore raw materials are different, remaining in steel material inside's impurities greatly not the same. These several models cross-national “twin” steel materials, in guarding against impurities' red line drawing on each has emphasis:

· National standard 45 steel: chromium element must not cross over 0.25%, nickel element cannot exceed 0.30%

· European standard C45: toward molybdenum element stuck very strictly, dead pressed at within 0.10%

· Japanese standard S45C: copper element's highest upper limit is set at 0.30%

Electric furnace refined out's American standard 1045, copper content extremely easily approaches 0.30%'s highest point. Milling machine downward hitting bottom hole time, cut down's iron chips breaking sound listens slightly muffled. European standard specification separately gave C45 (material number 1.0503) added a door sill of silicon element, requiring must not break through 0.40%. Japanese standard S45C frames silicon content between 0.15% to 0.35%. Toward molten steel inside scatter how much ferrosilicon alloy, manages steel ingot inside enough or not enough tight solid. Silicon content leaning high, turning diameter 60 millimeters' round steel, tool walking speed 0.2 millimeters time, alloy blade's life damaged 15%.

Europe sent coming's purchase order, on top frequently carries C45E or C45R's wording. Name tail on extra out's letters, represent steelmaking master toward sulfur element applied different fierce medicines:

· C45: conventional common version, sulfur content controlled at 0.050% below

· C45E: main hit purity, sulfur element is strictly limited at 0.035% within

· C45R: specially improve cutting configuration, sulfur content stays at 0.020% to 0.040%

Sulfur content 0.035%'s C45R under cutting fluid high speed washing, broken down iron piece length basically maintains at 15 millimeters up and down. Lathe chuck one minute turns 1200 circles, processed surface bright degree easily tests out Ra 1.6's data. Domestic steel factories in making GB/T 699's 45 steel time, masters are accustomed to aim carbon content at 0.45%'s dead center.

One root diameter 50 millimeters' hot rolled 1045 round steel, tensile's force data mostly at 580 MPa up and down jumps. Same thickness's S45C passing through 880°C warm keeping then naturally let cool, yielding's pull force dial steadily stops at 350 MPa above's scale. Part of America's hydraulic equipment drawings, specially specify adopting cold drawn out's ASTM A108 1045 material.

Outer circle dimension error shrinks to h9 level, completely saves going on lathe peeling skin's rough turning step. Hard pulling's force pushes tensile strength up to 650 MPa's high position, price is material becomes completely without elasticity, pulled broken after's elongation rate falls to 12% edge. Purchaser taking S45C's order buys back cold drawn 1045, sent onto CNC machine tool opening keyway, internally held back stress releases out, triggers three thousandths of bending deformation. Workers must first send material into heating furnace, do one time 200°C to 300°C's de-fire treatment.

German wind power flange drawing on, hangs 20°C room temperature under using pendulum hammer smashing steel block's testing indicator. C45 made out test block under heavy hit, absorbing impact's data must cross over 25 Joules passing line. Internal structure's particle thick thin, according to ASTM E112 standard taking microscope to look, must densely pack to 5 grade even more dense.

American standard derived out one model carrying letter H's 1045H, specially guarantees burn red quenching after's hardness performance. Use water column to spray one head burned red's steel pillar, away from spray water point 1.5 millimeters' place, hardness stuck between 55 to 62 HRC. Along pillar backward measure to 15 millimeters position, hardness naturally slides down to 30 to 45 HRC. Japanese standard S45C extremely rarely draws same kind curve graph, Japanese designers accustomed on drawing lead out one line, indicating induction copper tube heating's enter knife depth. Outer circle surface skin heated to 900°C then fiercely spray water, 2 millimeters deep place's hardness pulls up to 52 HRC, inside still is 180 HB's soft state, to shoulder machine starting time twisting's fierce force.

Europe's C45E molten steel pure without impurities, using ultrasonic flaw detector to sweep shoot, screen on representing defect's ripple is faint to extreme point. Take drill bit inward drill 200 millimeters' deep hole, drill bit tip avoiding impurities interference extremely rarely happens deflection, hit out's hole diameter error maintains at 0.05 millimeters within. Domestic making large hydraulic press base commonly uses diameter 300 millimeters' 45 steel block material. 3000 tons' forging machine fiercely smashes, internal thick big lumps completely rubbed broken. Material clamped onto heavy lathe, blade one minute scrapes away 80 meters iron skin, chipped out blue iron chips using temperature measuring gun one hit, heat approaches 400°C.

Industrial Components Application

Workshop inside cutting finished's S45C parts carrying anti-rust oil's warm heat, packed into wooden boxes sent toward various places assembly lines. This model steel material extremely rarely goes to build aviation engines, relying on reliable mechanical parameters holds up ground machinery's chassis. Drawing on's dimension labeling becomes real drive shafts and gears, stuffed into all kinds of machine casings interior.

One unit power 15 kilowatts' industrial water pump, motor rotating speed per minute 2900 revolutions, internal supporting impeller's main shaft often selects diameter 45 millimeters' S45C round steel. Water pump starting instant's torque generates extremely big shear force. Passed through quenching and tempering treatment's main shaft surface hardness reaches 28 HRC, shoulders coupling's repeated pulling tearing.

Machine tool main shaft toward material concentricity requirement extremely strict, length 800 millimeters' S45C shaft rod on CNC outer cylindrical grinder walks finish last one knife, runout tolerance limited at 0.02 millimeters within. Agricultural tractor's rear axle half shaft consumes massive same grade forged rough blanks.

Rough blank in 850°C furnace chamber inside keep warm two hours then down water quenching, thick strong shaft body can shoulder fully loaded 5 tons heavy object passing potholed road surface's bumpy impact.

Agricultural machinery repair factory's masters normally prepare a few roots diameter 60 millimeters' S45C optical shafts, meeting broken open's drive rod, cut down one section throw onto lathe, half an hour turns out a replacement piece.

Relying on occlusion transmitting power's gear box inside, S45C often is used to cut medium carrying load's straight gears and helical gears. Module set as 4's reducer driving gear, gear hobbing machine tool head on circular disk gnaws out 25 tooth fangs. Gear put into induction coil heating, tooth surface hardness instantly pulls up to 50 HRC.

Gear's tooth root location has not completely quenched through, retaining 220 HB's original hot rolled hardness. Outside solid hard inside soft, gear under per second 15 meters linear speed occludes runs, extremely rarely happens whole tooth fracture phenomenon. Crane winch inside's double row chain wheel, selects thickness 40 millimeters' S45C steel plate gas cutting down material milling out tooth shape.

Large steel structure bridge's connecting locations densely packed fully cover hexagonal bolts. Market on labeled 8.8 grade's high strength fasteners, mostly use cold heading process taking S45C wire rod squeeze shaping. One root M24 specification's 8.8 grade bolt bears minimum 800 MPa's pulling force, guaranteeing steel beam under heavy load crushing not loose.

Mine stone crusher's heavy flange plate fastening homework, drawing specifies nut bearing 500 Newton-meters' tightening torque, S45C turned out's thick nut thread at this moment exempt from sliding silk.

Excavator boom and arm connecting place's pin shaft bears several tons mud's huge lever force. Diameter 80 millimeters' S45C pin shaft surface passed through induction quenching, outer layer plated on 0.05 millimeters thick's hard chromium. Coordinating butter lubrication, pin shaft in mud sand environment inside every day rubs over ten thousand times, supports passing 3000 hours maintenance cycle.

Plastic injection mold factory's shelf on neatly piled placing various specifications' S45C thick steel plates. Producing TV set back shell's heavy mold, bottom bearing pressure mold plate dimensions reach 1200 millimeters multiply 800 millimeters. Thickness 150 millimeters' steel plate sent into large gantry milling machine, flying cutter head one minute cuts off 2 kilograms iron chips milling out reference surface.

Injection machine screw with 150 MPa's pressure takes melted plastic hit into mold cavity, S45C mold base shoulders this burst of swelling force:

· Guide pillar guide sleeve installation hole: coordinate boring machine processing hole diameter error less than 0.005 millimeters, guarantees mold opening closing smooth

· Cooling water channel: deep hole drill hits out diameter 12 millimeters' water road, bearing 10 kilograms pressure's cooling water circulation

· Bearing pressure pad block: cut into 50 millimeters square's small blocks, dispersing thousands of tons' locking mold force

Diesel engine inside piston and crankshaft between's connecting rod often selects S45C die forging piece. Thousands of tons' forging press takes burned red's steel rod one hammer smashes into mold cavity body, squeezes out connecting rod prototype. Forging action changed material internal's metal flow lines, along connecting rod contour distributed's metal texture pulled high anti-fatigue pulling dragging's ability.

Hydraulic oil cylinder's cylinder bottom and cylinder cover consuming large batch S45C round steel. Outer diameter 120 millimeters' hydraulic cylinder sleeve two heads welded on S45C turned out's circular end covers. Carbon dioxide shielded welding's welding wire at end cover bevel groove place melts, weld seam place steel material receiving heat reaches 1500°C above. Annealed let cool's cylinder cover shoulders 25 MPa high pressure oil impact.

1045

Mass Fraction

100 jin's steel material inside after all packed what things. Steelmaking furnace's molten steel weight reaches 5 tons, workers toward inside pour materials, weighing scale on's numbers decided steel's hard temper. Carbon's weight is dead stuck between 21.5 jin to 25 jin, also is 0.43% to 0.50%'s matching ratio. Extra add half a jin carbon, quenching after's Rockwell hardness dial pointer then upward jumps 0.5 HRC. Tensile strength testing machine on's pull force data easily rushes breaks 600 MPa.

Carbon's jin number less, lower than 0.43% this line, soaked in water inside rapidly cooling also hard not up. Lathe spindle using containing carbon 0.41%'s material, turns 300 hours, bearing position's metal is ground off 0.02 millimeters. Only relying on carbon supports not up steel material's toughness, still have to toward 5 tons molten steel inside throw 30 jin to 45 jin's manganese. Manganese element once enters, steel material internal crystallizing's temperature drops 20℃.

Natural cooling 4 to 6 minutes, steel material cut surface's crystal grain size becomes 5 to 8 grade. Quenching tank's cold water bumping into burned red's steel, 0.80%'s manganese lets quenched through layer extra 3 millimeters. Gear milling cutter cuts down, hard alloy blade received's resistance less 12%. Factory inside's quality inspection sheet toward various residual ingredients' weight nitpicks very fine, laboratory's tray balance accurate to 0.001 grams.

· Silicon weight proportion: 0.17% to 0.37%

· Copper weight proportion: highest 0.25%

· Nickel weight proportion: at most 0.20%

· Chromium weight proportion: pressed at 0.15% inside

· Molybdenum weight proportion: not exceed 0.10%

Spectrometer one day shines 15 times. Sulfur and phosphorus these two kinds of impurities' weight is set dead at 0.050% and 0.040%. Iron ore brought in's sulfur overweight, 1100℃'s forging machine one smash, 5 tons' steel ingot straight drops dregs. Containing sulfur amount over 0.060%, 988℃ time metal border place then melted. 1200 tons pressure's rolling steel machine one press, steel plate surface cracks open 0.5 to 1.2 millimeters' seam.

Phosphorus more, arrived at zero below 20℃'s place, Charpy impact work falls away 40%. Polar region hitting well used's steel parts, bearing 30KN lateral force will directly brittle break. Putting aside these, remaining's 98 jin all is pure iron. 25℃ room temperature under, iron atoms align into crystal lattice, spacing 0.286 nanometers. Not burned passed's iron lump elongation rate has 16% to 20%.

· Carbon match 0.45%: before weld heat 200℃

· Manganese match 0.80%: quenching oil temperature 60℃

· Silicon match 0.25%: casting shrinkage holes less 15%

· Phosphorus press 0.02%: low temperature toughness good

Lathe 1500 revolutions/minute, containing sulfur amount 0.035%'s steel, cut down's iron chips curl into C shape. This 0.035%'s weight ratio, exactly lets iron chips easily break. Quality inspector takes hard alloy drill bit, on steel rod hits 20 millimeters deep hole. Digs out 50 grams iron chips stuffs into carbon sulfur analyzer, 1250℃ burns 3 seconds. Infrared probe 45 seconds reports number, printer spits out paper strip.

Sheet on writes C: 0.46%, Mn: 0.75%. CNC lathe cutting fluid flow rate opens to per minute 8 liters, milling cutter takes surface roughness cuts to Ra 1.6 micrometers. Differed 0.01%'s matching weight, machine's changing parts time table has to all rewrite. Worker holding micrometer, measures out processed good's flange plate outer diameter tolerance stuck at 0.03 millimeters inside.

Heat treatment workshop's quenching liquid concentration maintains at 8%, 600℃'s tempering furnace opened 4 hours. Batching scale on's every one gram jump, all are changing metal's physical occluding force. One unit heavy reaching 3 tons' CNC machine tool, every day consumes away 50 handles coated blades, cutting complies with weight matching ratio's steel rod. 100 jin steel material's formula sheet, all relies on decimal point after three places' weighing records supporting.

Mechanical Parameters

Hydraulic tensile testing machine's jaw bites dead one root diameter 20 millimeters' round steel. Oil pump adds pressure to 180 kilonewtons, metal rod's middle section naked eye visibly becomes thin. Pull force dial numbers climb to 570 MPa's scale line, accompanied by one sound muffled bursting noise, steel rod on tensile machine breaks into two sections.

Pointer stuck at 340 MPa's number on trembles, metal starts to generate unable to recover's plastic deformation. Remove away hydraulic cylinder inside's pressure, original 1000 millimeters long's steel rod returns not to original dimension, lively was pulled long 2 millimeters.

Strictly tight seam fit together, originally marked's 100 millimeters test area became 116 millimeters. Vernier caliper read out's 16% elongation rate, lets cold processing punching machine in mold inside squeezing this piece steel plate time, will not hear shattering's brittle sound.

Just out furnace annealed's rough steel blank thrown on Brinell hardness tester's test table. Diameter 10 millimeters' tungsten carbide alloy ball aims at blackened surface. 3000 kilograms' counterweight weights press down 15 seconds, surface is smashed out one diameter 4.5 millimeters' round pit.

Measuring micro eyepiece inside's cross crosshair aims at round pit edge, machine converts out 190 HB's hardness value. Not passed through quenching's rough blank all year round maintains in 163 to 207 HB's hardness interval. CNC lathe changed onto common hard alloy blade, per minute eat knife deep 2 millimeters not a bit strenuous.

Copper made induction coil sleeves one root diameter 40 millimeters' steel shaft. 850℃'s red light on surface stays 3 seconds, spray water ring with per minute 60 liters' water amount fiercely rushes, bearing position surface temperature within 2 seconds plummets. Martensite structure in extremely fast cooling inside squeezes full surface layer, taking outer side's hardness forcibly topped up.

Rockwell hardness tester top end's 120 degree diamond cone presses into quenching after's shaft neck. 150 kilograms force presses solid, scale dial's pointer points at 52 HRC. Fitter takes new steel file on surface forcefully pushes, only leaves extremely shallow one stroke white mark, even a little bit metal crumbs all scraped not down.

Grinding wheel machine takes this root quenched shaft from middle cuts break, drips on acid washing liquid. Outer ring 1.5 to 2.5 millimeters' thickness becomes deep gray color, all is strengthened hardness layer. Toward circle center look color leans white, hardness test hits down only has 200 HB, soft quality's inner heart responsible in machine starting time absorb fierce vibration.

Mechanical laboratory's destructive testing equipment every day produces out in batches' sheets:

· Charpy V-notch impact absorbing work: 39 Joules

· Rotating bending fatigue limit test: 275 MPa

· Elastic modulus physical calibrating data: 205 GPa

· Anti-shear limit stress destroying point: 430 MPa

22.5 kilograms' impact pendulum hammer hoisted high 1.5 meters. Operator steps down pedal, pendulum hammer with per second 5 meters' speed fiercely smashes carrying 2 millimeters deep V-notch's square steel block. Metal eats down 39 Joules' destruction energy, test block breaks into two halves flies out full of scratch marks' test table.

Torque meter reading rushes up 800 Newton meters, one meter long's steel rod like fried dough twist same was lively twisted two circles and a half. Surface just emerged leaning 45 degrees' tiny tearing crack lines, inner ring's low hardness structure is dead dead dragging fast going to break open's outer side metal.

Fatigue machine on's eccentric wheel per minute runs 3000 revolutions. To metal applies 250 MPa's alternating stress, continuously operates 10 million times cycle. Cut down receiving force section take to microscope under magnify 500 times, surface find not arrive even one piece 0.01 millimeters long's metal fatigue crack line.

Pin disk wear machine applies 50 Newtons' vertical weight. Without lubrication dry grinds 200 hours, runs finish 120 kilometers' friction journey. Take to one thousandth gram precision's electronic scale on pass pound, 55 HRC's quenching face merely dropped down 0.05 grams' metal powder.

Crane reducer box's module 4 straight gear runs at 1500 revolutions per minute's speed under. Outer layer 50 HRC's hardness prevented tooth surface's iron chip peeling off. Tooth root place's 16% elongation rate shoulders down motor every time fully loaded starting brought coming's physical pull drag.

Tower crane on's M24 double head bolt hoists up 5 tons heavy's cement board. Metal internal bears 220 MPa's longitudinal pull force. Unload down counterweight block, 205 GPa's elastic modulus lets metal crystal lattice instantly shrink return position, thread go no-go gauge screws in entirely without stuck pause.

Machining Service

Cutting & Material

Take 45 steel put at microscope under magnify 500 times observe, internal structure is one piece soft one piece hard's mixed state, crystal grain size stays at ASTM 5 to 8 grade. That kind leaning soft's material quality at bumping into cutting blade tip time, will be hard lively torn pull open, surface leaves behind one layer naked eye cannot see clearly's tiny burrs.

Lathe with per minute 30 to 50 meters' speed slow speed runs, friction force takes blade front end heats up to 300 degrees. Soft steel chips at this temperature under stick on blade tip on, pile up out one 0.1 to 0.2 millimeters high's small pimple. Knife mouth shape changed, cut out's surface touching up extremely rough, numerical value exceeded Ra 6.3 micrometers. Hit off this small pimple completely relies on interfering machine parameters:

· Machine lift speed runs to per minute 150 meters.

· Change onto carrying 2.5 millimeters wide chip breaker groove's blade.

· Blade tilting angle dialed to 15 to 20 degrees.

· Spray out 20 bars pressure's cooling water drop temperature.

Speed exceeds per minute 120 meters, cutting position's temperature rises up to 600 to 800 degrees. Exhaust chip tube inside fly out blue purple color's thick iron chips, thickness reaches preset value's 1.5 to 2 times. High temperature takes blade inside's metal cobalt bakes soft, hard alloy starts little by little downward drop.

According to requirement blade worn away 0.3 millimeters needs to hurry up change new, letting it wear will let made out's parts outer ring appear 0.02 to 0.05 millimeters' thick thin big small head. Old hands will straight stare at iron chips curling's arc, in advance 5 to 10 minutes then can guess blade fast going to chip mouth. Want to cut out Ra 0.8 micrometers that kind can reflect out human shadow's mirror surface effect, need fine control blade head:

· Pick one carrying 0.8 millimeters round corner's wiper blade.

· Every time walk knife distance stuck at 0.08 to 0.12 millimeters.

· Blade tip aims at center line, error not exceed 0.05 millimeters.

· Cutting fluid concentration add to 12% to increase lubrication.

Meet sulfur content approaching 0.035% upper limit's steel material, iron chips lightly loosely break into 15 to 20 millimeters long's C word shape broken blocks. Changed to containing sulfur amount not arrive 0.015%'s that batch goods, iron chips long like ropes same entangle on machine on.

Just bought back coming's rough steel rod internal every place receiving force completely not the same, cut away 3 millimeters thickness after, one root 400 millimeters long's shaft then bent 0.15 millimeters. Take it throw into furnace inside heat up to 550 degrees bake 3 hours, internal holding back's strength scattered, deformation amount shrank back to 0.03 millimeters within.

Quenching treatment took steel material hardness topped to HRC 30. Normal's coated knife cuts not moving, have to change onto CBN material quality's knife tools hard gnaw. Every time only cut 0.15 millimeters deep, machine hanging per minute 70 meters' slow speed, emitted out's hot gas takes iron chips surface scalds into dark red color.

Cutting strength too big causes machine tool a burst burst vibration, tool stretch out length reaches handle thick thin's 4 times, cut out's surface leaves behind interval 0.5 millimeters' wave lines. Toward hollow's tool holder inside pour high density's tungsten alloy blocks, vibration amplitude a few seconds drops to 3 micrometers below. For parts hit deep holes and drill threads, exhausting iron chips not smooth very easily gets broken drill bits:

· Drill bit spiral angle pick 28 to 30 degrees.

· Depth exceeds diameter 5 times, every drill 2 millimeters retreat one time knife.

· Squeezing bottom hole diameter subtract 0.02 millimeters margin.

· Tapping speed pressed at per minute 15 to 20 meters.

45 steel having 210 GPa's elastic modulus, self rigidity very sufficient. Hydraulic chuck uses 40 kg/cm²'s strength dead dead pinches part, meeting upon tube wall not arrive 5 millimeters' thin piece, loosening chuck's instant tube wall springs back 0.04 millimeters, inner hole becomes slight's three petal shape.

Grinder on's grinding wheel with per second 30 meters' speed rubs pass part surface, used to wipe flat lathe left behind's tiny errors. One time grind off exceeding 0.015 millimeters, surface layer 0.1 millimeters' metal is high temperature burned red. Cooling water pours down metal cold shrink not in time, surface chips out 0.05 millimeters deep's fine crack lines.

Processing large diameter flange plate bumping onto interrupted cutting, blade every second needs to bear tens of times impact. Feed amount opens to 0.4 millimeters, spindle maintains 800 revolutions per minute's rotating speed, huge impact force requires machine tool guide rail possess extremely high weight. Take cast iron bed body widen to 600 millimeters, machine tool self weight piles to 5 tons, cutting time's roaring sound is by base absorbed.

Turning carrying thread's slender shaft, very afraid parts under blade tip pushing force happen bending. At tail part top on one root Morse number 4's live center, applies 200 kilograms' pushing force tops parts one head. Tool at workpiece middle section cuts off 2 millimeters thick's metal, workpiece middle section loses support generates 0.1 millimeters' yielding amount, caliper measures out middle thick two heads thin.

According to drawing requirement do surface carburizing, needs toward material quality inside supplement carbon powder. Parts put into 900 degrees' carburizing furnace inside bake 8 hours, surface layer 0.8 millimeters' thickness sucked full carbon element. Take out throw into oil inside rapidly drop temperature, surface hardness tester hits up jumps to HRC 58, internal as usual maintains toughness.

Blade surface's coating than hair strand even more thin, thickness only has 3 to 5 micrometers. Arrived at 900 degrees high temperature environment, this layer film generated one layer dense's aluminum oxide taking molten steel blocks on outside. Friction coefficient from 0.6 dropped to 0.4, underneath's hard alloy obtained extremely good protection.

CNC Numerical Control Processing

CNC milling machine's spindle rotating speed soars to 8000 revolutions per minute, one handle diameter 12 millimeters' four flute flat bottom milling cutter plunges into 45 steel blank. Tool with per minute 1500 millimeters' feed speed transversely cuts open metal, iron chips like raindrops same smash on machine tool's protective glass on. This unit heavy reaching 6 tons' three axis machining center, bottom part uses four roots M24's anchor bolts dead dead anchored in concrete foundation inside.

Strong cutting force along tool holder transmits to spindle bearing, machine tool internal's servo motor instantly surges in 20 amperes' current to maintain rotating speed not drop. Once rotating speed falls exceeds 50 revolutions, blade cutting in's angle then will happen deviation, workpiece surface immediately leaves behind one stroke deep 0.02 millimeters' gnawing knife trace. Operator tightly stares at control panel on's load meter, numerical value long term stays at 85%'s warning line nearby.

Processing one carrying complex cavity's mold base, G code program fully has 40 thousand more lines. Computer inside's CAM software in advance calculated good every one root tool's walking route, error is compressed at 0.001 millimeters' level. Even if code inside missed writing one decimal point, spindle then will carrying tool with per minute 15 meters' speed one head crash toward fixture.

Cut away big piece metal's rough processing stage, tool eat knife depth set as 8 millimeters. Nozzle inside squirts out pressure reaching 30 bars' cooling liquid, forcibly taking cutting zone high reaching 600 degrees' heat flushes away, preventing tool burning entirely red. Water pump motor emits sharp buzzing sound, water tank inside 200 liters' emulsion liquid in half an hour inside then completed one time complete's internal circulation.

Rough processing finishing after, 45 steel internal's stress release will let the whole part generate extremely tiny twisting. Probe from tool magazine inside stretches out, at part four weeks lightly touches obtaining four coordinate point data. System according to these four points calculates out 0.03 millimeters' tilting amount, immediately alters following coming's fine processing program coordinate system compensates error.

Arrived at fine repairing dimensions' link, change onto blade tip circular arc only 0.2 millimeters' fine milling cutter. Every time only cuts thin thin's 0.1 millimeters metal, feed speed slow down to per minute 400 millimeters. Part surface's roughness numerical value taking advantage of trend drops to Ra 0.8, touching up just like mirror same smooth not leaving fingerprints.

A axis and C axis two rotating axes same time act, letting workpiece in air inside realize maximum 120 degrees' flipping tilting. Tool beginning to end with cutting face maintains vertical angle, exempts multiple times disassembling restarting clamping brought coming's 0.05 millimeters secondary positioning error.

Targeting complex parts' five axis processing, working procedure layout has strict before after sequence requirement:

· First use 63 millimeters diameter's face milling cutter sweep flat top face, remove 2 millimeters' black skin margin.

· Change onto 16 millimeters' rough milling cutter climb milling open rough, side face leave out 0.15 millimeters' fine processing margin.

· Call use U drill on solid material on hit out diameter 20 millimeters, deep 50 millimeters' bottom hole.

· At last use ball end knife with 0.05 millimeters' step distance toward 3D curved surface conduct clear root scanning.

Machine tool's thermal deformation is processing precision's big enemy, workshop temperature from morning's 20 degrees rises to noon's 28 degrees. Cast iron bed body receives heat expands, Z axis direction quietly stretched long 0.015 millimeters. Carrying thermal compensation function's machine tool relying on stick on column on's three temperature sensors, every interval 10 minutes toward system sends one time correction command taking error pull back come.

Processing big length diameter ratio's drive shaft, hydraulic tailstock provides 300 kilograms' push force tops another head. Turning tool from right toward left walks tool, walks to middle position time workpiece receives force generates 0.08 millimeters' bending yielding. CNC program inside specially joined taper compensation code, in middle section forcibly lets tool toward inside extra cut 0.08 millimeters.

Cut down coming's iron chip shape not only with material quality has relation, also can reflect out CNC program's rationality:

Operator takes micrometer stuck on just cut good's cylindrical face on, twists force measuring ratchet emits three sounds crisp click noises. Reading displays outer diameter dimension is 40.012 millimeters, exactly stuck at drawing requiring's +0.01 to +0.02's tolerance band middle. Recorder takes measured out's numerical value knocks into beside's SPC quality control system, screen on immediately jumps out one representing qualified's green scatter point.

On 45 steel digs out width depth ratio reaching 1:5's deep groove, common tools extremely easily happen yielding tool bouncing. Installed on big length diameter ratio's customized milling cutter, rotating speed pressed low to 2500 revolutions, eat knife amount changed to every time downward walks 0.5 millimeters. Iron chips little by little toward outside exhaust, final measures out groove mouth up down two ends' consistency error not exceeded 0.02 millimeters.

Press down green button, work table carrying processed good's part drops down go, new tray in 12 seconds inside rotates 180 degrees enters processing cabin. Spindle stopped down coming's time not arrive 15 seconds, changed good blade once again roaring plunges into ice cold's metal inside.

Hydraulic fixture bottom's locating pin passed through 58HRC's quenching treatment, guarantees high strength using half a year also not deform. Steel block put up going's instant, pressed stuck bottom's air detecting hole, system detects 2 atmospheres' back pressure then will start clamping jaws. This set idiot proof design thoroughly blocked part not placed flat then was cut off 0.5 millimeters' scrap accident.

Used high grade's equipment and tools, 45 steel every batch between's 0.02% carbon content floating still will change cutting sound. Old master stands at one meter outside, hears low deep's cutting sound became ear piercing's high frequency scream. He one handful slaps down red color's emergency stop button, opens cabin door discovers blade edge already chipped off one 0.5 millimeters' small gap.

In order to rush out that batch 100 thousand pieces' automobile connecting rod order, macro program code inside's empty load moving speed was pulled to per minute 48 meters. Tool in two hole positions between fast shuttles, single time walking position saved 0.5 seconds. Relying on squeezing dry machine tool extreme speed, same one day shift 8 hours can extra cut out 300 pieces parts.

30 bars' high pressure water from drill bit tip end's two small holes inside squirts out, takes hole bottom's debris forcibly flushes to outside. Rotating speed pulled high to 3500 revolutions per minute, only uses 4 seconds then hit through one piece 30 millimeters thick's steel plate, hole wall clean clean without one bit spiral shape's pulling scratch marks.

For hydraulic cylinder tube turn slender internal thread, common taps will be blocked dead's iron chips held broken. Change to use single tooth thread milling cutter, tool one side self rotates one side along hole wall does spiral upward's interpolation motion. Milled out's M30 internal thread, take go no-go gauge to twist, go end smoothly to bottom, no-go end twists in one circle and a half steadily stuck.

Quality Control & Inspection

45 steel rough blanks transported to factory, inspector hand inside holding hand held type spectrometer sticks on steel tube surface. Pull down trigger 3 seconds, screen on jumps out carbon element content 0.46%, manganese element content 0.65%. This batch furnace number as XG882's steel material conforms to GB/T 699 standard requirement, carbon content steadily falls in 0.42% to 0.50%'s qualified interval.

Material quality sheet on's data no matter how pretty, cannot replace physical level's deep flaw detection. Internal hiding comparing sesame even smaller's air holes, cutting to half will let whole piece finished product thoroughly scrap.

Smear on dedicated couplant, ultrasonic flaw detector's probe sticking to round steel surface slowly slides. Emitted out's high frequency sound waves penetrate 200 millimeters thick's metal layer, meeting internal shrinkage holes or tiny crack lines will immediately reflect back come. Oscilloscope on's wave shape suddenly appears one height exceeding full screen 20%'s sharp peak, judging internal exists equivalent diameter 2.5 millimeters' defect, whole root steel rod is drawn on red color cross mark returned to steel factory.

First article inspection (FAI) is batch starting machine before's dead order. Worker takes just cut good's first piece part carefully holds into constant temperature measuring room. Air conditioner takes indoor temperature thunder striking not movingly locks dead at 20 degrees, humidity maintains at 45%. Part needs to at granite measuring table on statically lay two hours, let metal internal temperature and room temperature completely consistent, forcibly eliminate away that 0.005 millimeters' thermal expansion cold shrinkage error.

First article sent for inspection covers drawing on's all dimension labelings:

· Use micrometer stuck on outer circle measure three times, confirm diameter 45.015 millimeters at +0.01 to +0.02's tolerance band inside.

· Thread gauge twists into M20's inner hole, go end smoothly to bottom, no-go end at rotating one circle and a half time is dead dead stuck.

· Take part put on V shape iron on, rotate one circle, dial indicator pointer's swing amplitude strictly controlled at 0.01 millimeters inside.

Coordinate measuring machine (CMM) took over naked eye and caliper see not out problems' complex curved surface. One root carrying 2 millimeters ruby small ball's carbon fiber measuring stylus, according to computer set good's path, with per second 5 millimeters' speed touches metal surface. Collected 300 coordinate points after, software calculates out profile deviation is 0.012 millimeters, smoothly got allowed large batch producing's green light signature.

Lathe blade wearing will let dimensions quietly run deviating, relying on artificial memory not as good as relying on hard ruled sampling inspection frequency.

Quality inspector pushes loaded full measuring tools' small cart at lathes between back forth walks moves, sampling inspection frequency set at every 50 pieces checks one time. Surface roughness tester's stylus on just turned good flat face on slides 10 millimeters, screen displays Ra 1.6 micrometers. Beside's operator according to this micro adjusted machine parameters, took cutting speed per minute lifted 15 meters, next one piece product's finish degree dropped to Ra 0.8 micrometers.

Passed through quenching and tempering treatment's 45 steel parts need hardness test guard gate. Take surface grind away 0.5 millimeters' decarburized layer, put into Rockwell hardness tester's test table on. Diamond indenter carrying 150 kilograms' load presses into metal, dial on's pointer shakes a few times stops at HRC 32. Continuously hit three points, hardness value floating not exceeded HRC 1.5, confirms heat treatment furnace's temperature control extremely uniform.

Quenching after's inner hole coaxiality inspection uses pneumatic measuring instrument. Take carrying two nozzles' measuring probe plug into diameter 50 millimeters' deep hole inside. Compressed air from nozzle sprays out hits on hole wall on, according to gas rebounding's tiny pressure change, glass tube inside's buoy up down floats. Naked eye can clearly read out 0.002 millimeters' tiny taper error.

Tool room's drawers inside lie hundreds of handles passed through third party calibrated thread plug gauges. Every using 500 times, metrologist will take optical length measuring instrument toward plug gauge's thread profile angle restart scan one time. As long as wearing amount exceeds 0.003 millimeters, whole handle measuring tool will be forcibly scrapped, absolutely not let become thin's plug gauge let pass any one piece thread rotten tooth's part.

Arrived at packaging out warehouse before's last one stroke checking gate, full inspection assembly line opens:

· Image measuring instrument scans chamfer dimensions, takes 0.5×45°'s chamfer magnifies 50 times projects on screen on to inspect.

· Smooth plug gauge one by one tests pin holes, eliminates away those 3 pieces because bottom hole residual iron chips caused tolerance shrinking's defective products.

· To every batch 1000 pieces parts equip one copy EN 10204 3.1 material quality certificate, attached with complete's dimension inspection record sheet.

Magnetic particle flaw detector responsible to catch out part surface naked eye cannot see's tiny crack lines. To part connect on 3000 amperes' DC current, on surface spray mix with fluorescent powder's magnetic suspension liquid. Turn off top light turn on ultraviolet black light lamp, fine's crack line place will adsorb magnetic powder, in darkness emits eye piercing's yellow green color fluorescence, length only has 1 millimeter's pulling scratch has nowhere to hide shape.

Probe thickness tester used to inspect surface blackening treatment's oxide film quality. Magnetic probe vertically sticks on part blackened shiny surface, detecting instrument emits beep one sound. Reading stays at 4 micrometers, this thickness's ferrosoferric oxide thin film can let part in salt spray testing box inside support pass 48 hours not rust.

Quality inspection data real time uploads to workshop's SPC control big screen on. Representing dimension fluctuation's CPK index stays at 1.67, explains current's machining process capability extremely sufficient. If certain root shaft's diameter continuously 5 pieces presents become thick's trend, system will cut off corresponding lathe's power supply, forcing worker to inspect blade is not is already chipped mouth.

Scrap box inside's every one piece iron lump all labeled numbers. Take defective products cut open do metallographic analysis, use data trace investigate every one stroke working procedure's mistake.

Laboratory inside's grinding wheel cutting machine cuts open one appearing crack lines' gear blank. Use resin mount good cut face, on polishing machine use 800 mesh's sandpaper polished 20 minutes. Drip on 4%'s nitric acid alcohol solution corrodes surface, put to metallographic microscope under magnify 100 times. Clearly saw network shape distributed's ferrite, confirms is heat treatment link cooling speed too slow caused cracking.

Targeting long distance ocean shipping's parts leave factory before need to extract 5 pieces do anti-rust packaging destruction test. Use VCI volatile corrosion inhibitor paper wrap parts, pack into vacuum pumped's aluminum foil bag inside. Throw into simulating sea on high temperature high humidity environment's aging box inside put 14 days, take out tear open packaging, metal surface as before maintains bright silver color, without any oxidation spots generated.

Inspection link's every one time caliper opening closing all correspond to drawing on's tolerance numbers. Measuring inner hole diameter uses inner diameter micrometer, takes three probes spread open tightly stick to hole wall. Twist tight ratchet after lightly shake look for smallest dimension point, reading locked at 60.025 millimeters. Actual measured numbers are by quality inspector using black signature pen filled into follow goods walk together's leaving factory inspection report sheet inside.