Technology and features of shell manufacturing and rolling

Application of metal shell

The integral part of the workpieces and structures are metal shells. They are used in aviation, rocketry, oil and gas, chemical industries, and shipbuilding as:

gaskets, walls, supporting elements; parts of welded structures (tanks, boilers, pipes); blanks for flanges, bandages, drums, pipes, rollers; casings for communications (sewerage, water supply, passages); ventilation elements, chimneys, flues; components of technological equipment.

The company produces shells with a length of 30-3100 mm, an outer diameter of 200-4500 mm, and a wall thickness of 2-100 mm. It is possible to carry out non-standard orders.

Manufacturing

A typical technological process for the production of shells includes the following stages:

1. Cleaning the workpiece (removing scale and traces of corrosion).
2. Performing straightening of sheet metal.
3. Marking blanks, cutting them.
4. Cutting sheets into blanks.
5. Preparation of edges for welding work.
6. Assembly of blanks.
7. Performing card welding.
8. Rolling (circular bending) of shells.
9. Welding joints.
10. Edit.
11. Control.

Edge preparation

The operation is necessary to obtain the required edge shape and get rid of defects that arose when cutting the sheet. The shape of the edges must meet industry standards, specifications and requirements. Methods for processing the edges of shells for welding should not lead to mechanical damage. Possible options:

• Preparation of edges using an abrasive wheel with cleaning on both sides of the sheet plane in the areas of cutting edges and points of future welding, at a distance of 40 mm from the ends.
• Cleaning the edges using an electric grinder, on a tile stand, until cracks, rust, and scale are completely removed.
• Processing of edges using the milling method is carried out by securing the workpieces on the tables of milling machines of one type or another. Milling tools are milling heads and cutters. The edges for transverse seams in the bottoms and shells are processed on lathes and boring machines.
• Local edge cleaning and small amounts of work are performed using a pneumatic chisel.

Manufacturing of shells

We provide services for the production of metal products from steel sheets up to 14 mm. On our CNC machine, made in Italy ROCCIA.

4-volt volks allow you to produce products of various shapes.

The shell is an open cylindrical or conical element of a metal structure (such as a rim, drum, ring, short pipe). The shells are made using the method. Sheet bending is carried out in rollers (sheet bending machine); thick sheet steel is deformed with preheating.

Shells are used in the construction, metallurgical, and oil refining industries. We receive the largest number of orders for the production of shells from machine-building enterprises.

Shells are produced for further use:

• in welded metal structures: apparatus, pipes, boilers, tanks, silos, reservoirs, containers;
• as a workpiece: steel bandages, flanges, bandage rings, crane drums, brake drums, conveyor drums, rollers, pipes, sub-bandage shells of rotary kilns and other elements of non-standard industrial equipment;
• in casings of highways and structures of supports of bridges, water pipelines, sewers, crossings;
• for the manufacture of industrial chimneys, ventilation pipes, flues.
• parts of process pipelines: welded bends, tees, reducers, stainless steel pipes, compensators, pipeline supports.
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Sheet metal rolling technology.

The welding and assembly shop has more than ten units of rolling equipment, including a three- and four-roll bending machine that allows bending sheets of 09G2S steel up to 3000 mm long and up to 14 mm thick. In this case, the minimum internal diameter of the resulting workpiece is 350 mm. The capabilities of the equipment make it possible to roll the sheet into various shell shapes: cylindrical, conical, spherical. Sheet metal is cut on a gantry gas-plasma metal cutting machine. Shell welding operations are carried out using support roller rotators, welding positioners and manipulators. Welding of longitudinal and circumferential seams can be performed using semi-automatic submerged arc welding units. Thermal equipment is represented by gas furnaces for normalizing and heating the workpiece. In accordance with the requirements for product quality and technical specifications of the customer, the company carries out 100% ultrasonic inspection of welds. At the customer's request, the company can machine the ends of the shell for welding on lathes and rotary lathes.

Moscow, St. Petersburg, Novosibirsk, Yekaterinburg, Nizhny Novgorod, Kazan, Chelyabinsk, Omsk, Samara, Rostov-on-Don, Ufa, Krasnoyarsk, Perm, Voronezh, Volgograd, Krasnodar, Saratov, Tyumen, Togliatti.

Application area

The shell pipe, the price of which is determined based on technical parameters, can be used in the following industries:

1. TU 1381-001-17454136-2013 is used in the construction sector, industry, and petrochemical fields.
2. The pipe according to TU 14-3R-56-2001 is used for the installation of general purpose pipelines that operate under high pressure. Such pipes are also used when laying oil and gas pipelines.
3. Pipe made from sheets in accordance with GOST 10706 is used in the construction industry, housing and communal services, etc.

Many industrial and construction companies use their own pipe , the size and configuration of which is formed based on their current needs. Such products can be used in the installation of protective and supporting structures, air duct systems, etc.

Household use

People began using shells in prehistoric times. That is, they included the side part of any cylindrical or conical dish, for example, a birch bark piece rolled from a piece of birch bark. When the production of tin buckets and basins was subsequently mastered, their side wall also served as a shell.

And outside of the dishes, what is the shell? This is primarily part of the resonator body of a wide variety of musical instruments - strings and percussion. A balalaika, a guitar, a double bass, and a drum have a shell. By the way, the shell of a drum is called a cadl.

With the development of casting technologies, sewer manholes acquired cast iron shells - this is the base of the manhole attached to a pipe or vessel, on which its cover is laid. Recently, both covers and shells of hatches began to be made of composite materials.

Another example of a shell is the well-known concrete ring from which well pipes are assembled.

Stages of shell manufacturing

Kaluga Experimental Mechanical Plant LLC is engaged in the manufacture of conical shells (as well as cylindrical shapes) in standard and non-standard sizes. The production is equipped with high-precision equipment, including Italian and German sheet bending machines. Finished products are of high quality and reliability.

The shell manufacturing process takes place in stages:

1. Purchase of materials, taking into account the thickness, dimensions, characteristics of the part that is planned to be manufactured.
2. Cut out the shapes according to pre-calibrated dimensions.
3. Rolling of shells. On sheet bending machines, a pipe (or pipes) of the desired shape is formed from metal sheets;
4. Welding. The next step is to weld the edges longitudinally and transversely, the seam is sealed and reliable;
5. Checking products for compliance with specified geometric parameters;
6. Checking seams. Specialists test welding seams for strength and tightness. The most popular control method is ultrasonic;
7. Delivery to the customer in a convenient way.

Industrial shell: what is it?

The side part of any cylindrical or conical vessel also represents one or a combination of several shells. When manufacturing nuclear or chemical reactor vessels, according to the requirements of designers, it is necessary to manufacture vessels that are under high pressure and in aggressive environments. Moreover, the length of such a vessel far exceeds the capabilities of foundries and machining machines.

There is a way out - the body is broken into parts. The side walls of the reactor are divided into several (up to ten) rings - cylindrical shells, each of which is sized to be cast and processed separately using existing equipment. After mechanical processing, which brings the dimensions of the body elements to the specified ones, they are connected together on welding stands several tens of meters long. The cover and bottom of the reactor vessel are also divided into segments, which are welded together and, at the last stage, welded to an assembly of several shells, thus achieving the integrity of the vessel.

For vessels of smaller sizes and lower pressure, a different method of making shells is used - they are not cast, but bent from steel sheets on rollers and welded or riveted along the longitudinal seam.

Rolling and bending

Metal rolling

In the procurement area of ​​the plant there is a rolling machine purchased for the manufacture of drying drums and other agricultural machines. Additionally, we provide rolling services for sheet metal with a thickness of 0.8 to 16 mm (for steel grade ST3).

It is possible to roll any rolled metal – pipes, channels, angles, rolled sheets, including flanged sheets. The relative position of the rollers determines the bending radius and the shape of the workpiece. The technology makes it possible to produce shells with a diameter from 300 to 3500 mm.

offers custom-made rolling and bending of sheet metal of any complexity. The workshops are equipped with the latest CNC machines - technological equipment for the production of agricultural equipment.

The high performance of the devices allows you to use their potential to provide metalworking services.

Thanks to the updated main production facilities, the plant offers affordable prices for sheet metal rolling and bending services in Nizhny Novgorod. The cost is affected by the complexity of the parts and the number of bends.

Metal processing time is two days.

To order the services of a bending machine or metal rolling, leave your details on the website. Our manager will call you back at a convenient time.