English
These precision machined flange assemblies are high-performance structural and connecting components crafted from premium stainless steel/alloy steel, integrating forging and CNC machining technologies. Engineered for industrial applications such as petrochemical, aerospace, and heavy machinery, they deliver exceptional dimensional accuracy (tolerance within ±0.01mm), superior mechanical strength, and excellent corrosion resistance. Designed to form leak-tight, high-pressure connections in piping systems and equipment interfaces, these flanges meet international standards like ASME/ANSI and DIN, ensuring compatibility and reliability in critical operating environments.
1. Material Selection
The flanges are fabricated from high-grade stainless steel (e.g., 304/316) or alloy steel (e.g., A105), selected for their robust tensile strength, fatigue resistance, and corrosion resistance. Raw materials undergo strict material certification and ultrasonic testing to eliminate internal defects, laying a solid foundation for the final product’s performance.
2. Manufacturing Process
• Forging: The billet is heated to 1000–1200°C and shaped via upsetting, punching, and expanding processes. This forging step refines the grain structure of the material, enhancing its density and load-bearing capacity by up to 30% compared to cast flanges.
• CNC Machining: Precision turning on CNC lathes achieves tight tolerances for the flange’s inner/outer diameter, sealing surface, and neck. CNC drilling/milling ensures accurate positioning of bolt holes and locating spigots, with repeatability within 0.005mm for key features.
• Heat Treatment: Normalization or solution annealing is applied post-forging/machining to relieve internal stress, prevent deformation, and optimize the material’s mechanical properties.
• Surface & Quality Inspection: The sealing surfaces are polished to a mirror finish (Ra ≤ 0.8μm) for leak-proof sealing. All flanges pass coordinate measuring machine (CMM) checks, pressure testing, and non-destructive testing (NDT) to confirm compliance with design specs.
3. Application Advantages
These flanges excel in high-pressure (up to 2500#) and high-temperature (≤600°C) industrial settings. Their one-piece machined design eliminates welding defects, while the precision-machined thread and sealing surfaces ensure easy installation and long-term stability. They are widely used in pipeline systems, reactor vessels, and mechanical equipment where secure, durable connections are essential.
1. Cold Heading Process: A cold heading machine is used to forge steel round bars at room temperature to form the main structures such as the nut head and shank in one operation. This process improves the density and strength of the metal and is suitable for mass production. 2. Thread Processing: Internal threads are made through thread rolling/tapping processes. Thread rolling produces threads with high precision and good strength, which is the mainstream thread processing method for wheel nuts. 3. Surface Treatment: First, heat treatment (quenching and tempering) is carried out to improve hardness, followed by electroplating (zinc plating/chrome plating) to achieve rust prevention and a bright appearance. In some cases, carburizing/nitriding treatment is also applied to enhance wear resistance. 4. Auxiliary Processing: Turning/milling is performed on the anti-theft sleeve (the left part) to create a special-shaped inner hole that matches the anti-theft nut, ensuring anti-theft compatibility.
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