Hydraulic Cylinder Tube Manufacturing Process Overview

Hydraulic cylinder tubes are an integral component in various industries, especially those involved in heavy machinery, automotive systems, and hydraulic systems. These tubes are specifically designed to provide structural support and seamless functionality in hydraulic cylinders, which are responsible for transferring power in hydraulic systems. Hydraulic cylinders rely heavily on the quality and precision of the tubes, as they are the main channels through which hydraulic fluid flows and applies force to achieve mechanical movement.

At Changzhou Chengxin Metal Products Co., Ltd., we have been specializing in the production of high-quality hydraulic cylinder tubes since 1998. Our expertise lies in both cold drawn steel tubes and ERW (Electric Resistance Welded) steel tubes, offering customized solutions that cater to different industrial needs. With the advancement in technology and demand for precision, our factory has adopted state-of-the-art machinery and production techniques to meet the growing needs of the industry.

The Importance of Hydraulic Cylinder Tubes

Hydraulic systems are used in a wide range of applications, from construction machinery and industrial equipment to transportation and manufacturing processes. The hydraulic cylinder tubes play a crucial role in ensuring the smooth operation of these systems. These tubes must possess exceptional strength, precision, and resistance to various environmental and operational factors such as pressure, heat, and corrosion.

Hydraulic cylinder tubes are typically manufactured using either cold drawing or ERW processes, each of which has distinct advantages based on the application and the desired properties of the tubes. Cold drawn steel tubes are known for their high precision, tight tolerances, and superior surface finish, making them ideal for hydraulic applications where smoothness and strength are paramount. ERW steel tubes, on the other hand, offer excellent dimensional accuracy and are widely used in industrial sectors requiring mass production.

Overview of Our Factory Capabilities

Our factory spans an area of 32,000 square meters, with 22,000 square meters dedicated to production facilities. Over the years, we have built a reputation as a reliable and innovative manufacturer, focusing on high-quality steel tube production. We have the capacity to manufacture up to 25,000 tons of cold drawn steel tubes and 15,000 tons of ERW steel tubes annually.

We are equipped with advanced hydraulic cold drawing benches and ERW mills, which allow us to offer a wide range of tube sizes and specifications to meet the diverse needs of our customers. Our cold drawn tubes are produced using two hydraulic cold drawing benches, with capacities of 300 tons and 250 tons, respectively. These powerful machines enable us to manufacture precision tubes with outer diameters ranging from 50mm to 325mm, while maintaining tight tolerances and ensuring superior surface finishes.

Our ERW production line consists of two ERW mills, one of which is a high-precision mill. This advanced equipment enables us to produce round, square, rectangular, and oval-shaped tubes, meeting the varied demands of our customers in industries such as automotive, machinery, and hydraulic systems. Furthermore, our ERW tubes are available in both bright and black finishes, providing additional options based on the specific requirements of each project.

Commitment to Quality and Innovation

At Changzhou Chengxin Metal Products Co., Ltd., we believe that quality is the cornerstone of our business. Over the years, we have continually invested in cutting-edge technology and process improvements to ensure that our hydraulic cylinder tubes meet the highest industry standards. We adhere to stringent quality control measures, starting from the selection of raw materials to the final inspection of finished products.

Our manufacturing process incorporates heat treating furnaces, honing machines, and skiving & roller burnishing machines, ensuring that each tube produced is of the highest quality. Additionally, we have implemented environmentally friendly production practices, such as recycling materials and employing high-frequency recovery methods to reduce pollution and waste. This commitment to sustainability not only helps preserve the environment but also ensures that our products remain competitively priced and of the best quality.

With over two decades of experience, our team of engineers and technicians has gained a deep understanding of hydraulic cylinder tube production. We work closely with our customers to develop solutions tailored to their specific requirements, offering customized steel grades, surface finishes, and tube dimensions to suit various applications.

Manufacturing Process Overview

The production of hydraulic cylinder tubes requires a highly controlled and specialized manufacturing process to ensure that the tubes meet the exacting standards required for use in hydraulic systems. At Changzhou Chengxin Metal Products Co., Ltd., we employ two main production methods for manufacturing these tubes: cold drawing and electric resistance welding (ERW). Each method is designed to produce high-quality tubes with the mechanical properties and dimensional accuracy necessary for demanding industrial applications.

Cold Drawing Process

The cold drawing process is one of the most precise methods for manufacturing steel tubes, especially when tight tolerances and a high-quality surface finish are required. This process involves pulling a tube through a die to reduce its diameter and increase its length. The process is called “cold” because it is performed at room temperature, which helps improve the mechanical properties of the steel, such as strength and hardness.

At our factory, we utilize two hydraulic cold drawing benches, with drawing capacities of 300 tons and 250 tons, respectively. These powerful machines enable us to produce cold drawn tubes with outer diameters ranging from 50mm to 325mm. The cold drawing process is particularly suitable for applications that require high precision and smooth surface finishes, such as hydraulic cylinder tubes, where even minor imperfections can lead to significant operational issues.

The key steps in the cold drawing process are as follows:

1.Tube Preparation: The process begins with the selection of high-quality steel billets, which are heated and formed into preliminary tube shapes. These tubes are then cut to length and inspected for any surface defects or inconsistencies.

2.Cold Drawing: The prepared tubes are drawn through a series of dies that gradually reduce their diameter and increase their length. The dies are precision-engineered to ensure tight dimensional control, allowing us to produce tubes with highly consistent outer diameters and wall thicknesses.

3.Heat Treatment: After cold drawing, the tubes undergo heat treatment in our heat treating furnaces. This process helps to relieve the internal stresses created during the cold drawing process and restore the ductility and toughness of the material.

4.Surface Finishing: The tubes are then honed or treated using skiving & roller burnishing machines to achieve a smooth internal surface, which is essential for hydraulic cylinder applications. These finishing processes help improve the surface quality of the tubes, reducing friction and wear in hydraulic systems.

5.Final Inspection: Before being shipped, each tube undergoes a rigorous final inspection to ensure that it meets the required specifications for size, straightness, surface finish, and mechanical properties.

Electric Resistance Welding (ERW) Process

The ERW process is a highly efficient method for producing steel tubes, particularly for applications that require mass production. In this process, steel strips are rolled into a tube shape, and the edges are welded together using electrical resistance. This welding process does not require additional filler materials, making it a cost-effective solution for producing high-quality steel tubes.

At Changzhou Chengxin Metal Products Co., Ltd., we operate two ERW mills, including a high-precision ERW steel tube mill. These machines allow us to produce ERW tubes in a variety of shapes, including round, square, rectangular, and oval, with outer diameters ranging from 8mm to 70mm. Our ERW tubes are available with bright, smooth finishes or black finishes, depending on the customer’s requirements.

The main steps in the ERW process are as follows:

1.Steel Strip Preparation: The process begins with a steel strip, which is formed by cold rolling and cutting the strip to the desired width. The quality of the steel strip is critical to the final product, so we ensure that only high-quality steel is used in our ERW production line.

2.Forming the Tube: The steel strip is fed through a series of rollers that bend it into a tubular shape. This step is crucial, as the precision of the rollers ensures that the tube dimensions are accurate and consistent throughout the length of the tube.

3.Welding: Once the tube is formed, the edges are heated using electrical resistance, which causes the material to fuse together. The welded seam is then passed through additional rollers to ensure that it is smooth and flush with the rest of the tube.

4.Cold Drawing (Optional): In some cases, we use our cold drawing benches to further refine the dimensions and surface finish of the ERW tubes. This step is particularly useful for applications that require tighter tolerances or improved surface quality.

5.Surface Finishing: Depending on the customer’s requirements, the ERW tubes can be treated with additional surface finishing processes to achieve either a bright or black finish. This step is particularly important for applications where aesthetics or corrosion resistance is critical.

6.Inspection and Testing: As with the cold drawn tubes, our ERW tubes undergo rigorous quality control checks, including dimensional inspection, weld integrity testing, and mechanical property verification. This ensures that each tube meets the high standards required for industrial use.

Combining Precision and Efficiency

The combination of cold drawing and ERW processes allows us to offer a diverse range of hydraulic cylinder tubes with exceptional precision and efficiency. Each method has its strengths, and our ability to employ both processes gives us the flexibility to meet the varied needs of our customers. Whether it’s the tight tolerances and smooth finishes of cold drawn tubes or the high-volume, cost-effective production of ERW tubes, Changzhou Chengxin Metal Products Co., Ltd. is equipped to provide solutions for any hydraulic cylinder application.

By integrating the latest technology and adhering to strict quality control measures, we ensure that our tubes deliver optimal performance in even the most demanding environments. This commitment to excellence has made us a trusted supplier to industries around the world, and we continue to innovate and improve our processes to stay at the forefront of tube manufacturing.