60 Series Thick Plate High-Efficiency Hydraulic Leveling Machine

Core Product Description & Technical Deep Dive

60 Series High-Efficiency Hydraulic Leveling Machine: Precision Stress Relief for Heavy-Gauge Plates

In the realm of heavy metal fabrication, simple "flattening" is no longer sufficient. The 60 Series Hydraulic Leveling Machine (designed for plate thicknesses ranging from 3mm to 60mm) goes beyond basic physical pressure. Engineered on the principles of elastoplastic deformation theory and the Bauschinger Effect, our system systematically eliminates internal residual stresses, achieving a stress relief rate of 85%-95%.

Core Working Principles & Engineering Excellence:

Harmonic Attenuation Straightening: Unlike standard levelers, the 60 Series utilizes a sophisticated multi-roll structure (19-high or 21-high configurations). As the plate passes through, it undergoes a precise "S-shaped" trajectory: entering with a large bending radius to eliminate macro-waves, transitioning through medium bends to address mid-scale wrinkles, and exiting with micro-bends for fine-tuning. This gradually converts varying curvatures into a single, flat plane.

Micron-Level Closed-Loop Hydraulic Control: Distinguishing itself from traditional semi-hydraulic systems, the 60 Series is equipped with an imported, fully automated hydraulic system. The control unit boasts a calculation speed of 0.01ms, working in tandem with high-precision displacement sensors to make micron-level adjustments to the roll gap. Even when processing parts with abrupt cross-sectional changes, the integrated leveling gap adjustment mechanism ensures a constant gap, fundamentally preventing workpiece collapse, sickle bends (camber), and roller indentations.

Real-World Performance Data (Field Test Report)

Test Material: Q345B High-Strength Steel Plate, 25mm Thickness

Initial Condition: Edge waviness of 15mm/m with significant internal stress warping.

Post-Leveling Result: After a single pass, flatness was consistently controlled within 1mm/m. Residual stress was reduced to below 30MPa, fully meeting the stringent requirements for subsequent precision laser cutting and robotic welding.

FAQ

Q: How does the 60 Series effectively eliminate springback when leveling high-strength thick plates (e.g., Q690 or Hardox)?

A: Springback is the biggest challenge in heavy plate leveling. Unlike traditional machines that rely on brute force, the 60 Series utilizes a dynamic zone-leveling technology combined with a material memory compensation algorithm. By applying independent hydraulic pressure to specific zones and predicting the material's rebound trend in real-time, the machine applies precise counter-force. Field tests show this reduces the 24-hour rebound rate of 16mm high-strength steel from the industry average of 30-40% down to less than 5%, ensuring the plate stays flat after laser cutting.

Q: Can this machine remove internal residual stress, or does it just flatten the surface visually?

A: It does much more than just visually flatten the surface. True leveling is about stress redistribution, not just physical pressing. The 60 Series forces the plate through a precise "S-shaped" bending path with multiple rolls, creating differential plastic elongation between the surface and core fibers. This process eliminates 85%-95% of internal residual stress. A simple verification method is the "cross-cut test": after leveling, if you cut a cross into the plate and the gap does not open or shift, the internal stress has been successfully neutralized.

Q: Is the roller gap adjustment manual or automatic? How precise is it?

A: The 60 Series features a fully automatic hydraulic gap adjustment system. Unlike older mechanical screw-down models that require manual stopping and adjusting, our system allows for micron-level precision (0.01mm) via the PLC touch screen. Operators can save specific parameter sets for different materials (e.g., "20mm Q345B" or "10mm Stainless Steel") and recall them instantly, significantly reducing setup time and eliminating human error.

Q: Why does the leveling speed need to be adjustable, and what is the recommended speed for thick plates?

A: Speed directly affects the "deformation sufficiency." If the speed is too high, the plate "floats" between the rolls without undergoing sufficient plastic yield, leading to "false flatness" (it looks flat but springs back later). For thick plates (>10mm) and high-strength materials, we recommend a lower speed (typically 4-10 meters/minute) to ensure the bending force penetrates to the core of the material. The 60 Series allows variable speed control to perfectly balance efficiency with leveling quality.