Manufacturing Process and Technology for Hydraulic Cylinder Tube​

Manufacturing Process and Technology for Hydraulic Cylinder Tube

The production of hydraulic cylinder tubes at Changzhou Chengxin Metal Products Co., Ltd. involves advanced manufacturing techniques to achieve high precision, durability, and performance. Our manufacturing capabilities include both cold drawing and ERW (Electric Resistance Welding) processes, each optimized to meet the specific needs of our customers across various industries. In this section, we will explore the processes, equipment, and technologies employed in our factory to produce high-quality hydraulic cylinder tubes.

Cold Drawing Process for Hydraulic Cylinder Tubes

The cold drawing process is a core method used to enhance the mechanical properties and precision of hydraulic cylinder tubes. It involves drawing a steel tube through a die to reduce its diameter and improve its surface quality. This process is performed at room temperature, which ensures better mechanical strength and dimensional accuracy compared to hot-rolled tubes.

1. Hydraulic Cold Drawing Benches

• Our factory utilizes two hydraulic cold drawing benches with 300 tons and 250 tons of power, allowing us to produce tubes with outer diameters (OD) ranging from 50mm to 325mm.

• These benches apply immense force to pull the steel tube through dies, creating a smooth internal and external surface.

2. Heat Treatment and Annealing

• After the cold drawing process, tubes are heat-treated to relieve internal stresses and improve ductility.

• We employ three heat treating furnaces to ensure uniform heat distribution, enhancing the material’s mechanical properties.

3. Honing and Skiving & Roller Burnishing Machines

• Honing: Four honing machines are used to achieve a high degree of internal smoothness, which reduces friction and ensures efficient operation in hydraulic systems.

• Skiving & Roller Burnishing: Our two machines are capable of handling tubes with a burnishing length of up to 9 meters, achieving perfect ID tolerance and bore roughness for critical applications.

ERW Process for Hydraulic Cylinder Tubes

The Electric Resistance Welding (ERW) process is used to manufacture tubes by welding the edges of steel sheets or coils. ERW tubes are known for their cost-effectiveness and reliability, especially for structural applications and medium-pressure hydraulic systems.

1. High-Precision ERW Mills

• We operate two ERW mills, including a high-precision mill designed to produce tubes with tight tolerances.

• The mills produce tubes in round, square, rectangular, and oval shapes, with OD sizes ranging from 8mm to 70mm.

2. Cold Drawing of ERW Tubes

• To enhance the surface quality and precision of ERW tubes, we utilize 3-chain cold drawing benches to further process these tubes.

• This additional step ensures that the ERW tubes meet the high standards required for hydraulic cylinder applications.

Inspection and Quality Control Systems

At Chengxin, quality control is an integral part of our manufacturing process. We implement strict inspection procedures at every stage, from raw material selection to final product testing.

1. Advanced Cutting and Straightening Equipment

• We use automatic cutting machines to ensure precise length tolerance within 1mm, with cut straightness controlled to within 0.5mm.

• Multiple roller straightening machines help maintain tube straightness to within 1mm per 1000mm, ensuring flawless installation in hydraulic systems.

2. Non-Destructive Testing (NDT)

• We employ ultrasonic and eddy current testing systems to detect surface defects and internal imperfections.

• Magnetic flux leakage systems provide additional assurance of material integrity, ensuring that each tube meets the required specifications.

Key Benefits of Our Manufacturing Process

• Dimensional Accuracy: Cold drawing and skiving processes ensure precise OD and ID tolerances, essential for hydraulic cylinder tubes.

• Surface Quality: Honing and roller burnishing provide a smooth finish, minimizing friction in hydraulic systems.

• Mechanical Strength: Heat treatment enhances tube strength, making them suitable for high-pressure applications.

• Customization: Our production lines are flexible, allowing us to produce tubes in various sizes, shapes, and steel grades based on customer requirements.

Sustainability and Innovation in Manufacturing

At Chengxin, we are committed to sustainable production practices. Our manufacturing processes are designed to minimize waste and improve energy efficiency:

• We recycle offcuts and waste materials generated during production to reduce environmental impact.

• Our heat treatment furnaces utilize advanced energy-saving technologies.

• Continuous investment in research and development allows us to innovate, with recent developments including cold-drawn shaped tubes and advanced production equipment.

Our combination of state-of-the-art equipment, strict quality control, and innovative manufacturing processes ensures that we can meet the most demanding requirements for hydraulic cylinder tubes. Whether for automotive, construction, or machinery industries, our tubes provide unmatched performance, durability, and reliability.

Up next, we will cover the Product Specifications and Range of Hydraulic Cylinder Tube, detailing the dimensions, materials, and customization options available to our customers.