Fabricating & Machining a 45-Ton Structural Machine Base
The Project Challenge
A leading global manufacturer of massive industrial press machines approached Openex to fabricate and machine the foundational base for their new 3,000-ton stamping press. The structural bed needed to be over 14 meters in length, endure immense continuous vibrations, and carry a massive operational load without flexing or warping.
The primary engineering challenge: When heavily welding massive carbon steel plates (up to 120mm thick) together, massive thermal stresses build up inside the metal. If the machine bed was CNC milled without proper heat treatment, the residual internal stresses would eventually cause the massive bed to slowly warp out of tolerance over time, destroying the press machine.
The Openex Solution: Step-by-Step Execution
Precision Cutting & Fit-Up
Thick Q345 / A572-50 carbon steel plates were precision cut using our heavy-duty CNC plasma cutters. Plate edges were aggressively bevelled to allow for the extremely deep weld penetration required for heavy cyclical loading.
Massive Submerged Arc Welding (SAW)
Because of the frame's 45-ton size, standard fabrication shops struggle to manipulate it. Openex utilized 100-ton turning rolls and overhead cranes to ensure that every major structural seam was positioned in the optimal 1G (flat) position, utilizing Submerged Arc Welding to rapidly and flawlessly fill the heavy bevel joints. 100% UT (Ultrasonic Testing) was applied to the structural joints.
Thermal Stress Relief Furnace
After all fabrication, lifting lugs, and gussets were welded in place, the entire 14-meter machine bed was driven directly into our massive on-site heat treatment furnace. Post-Weld Heat Treatment (PWHT) relieved all internal residual welding stresses, neutralizing the frame into a stable block of steel that would never naturally deform.
5-Axis Planer Milling
With the structural base stress-relieved, we moved it onto the 20-meter bed of our colossal Waldrich Coburg CNC Gantry Mill. Our master machinists faced the massive linear guide-way tracks and motor mounting pads down to an exacting flatness tolerance of ±0.03mm per meter, completely ensuring vibration-free movement.
Heavy Planer Milling on Gantry CNC
Passed CMM Inspection
Project Success & Value Delivery
By managing the entire production cycle (Material processing → Welding → Heating → Heavy Machining → Painting) entirely inside our own massive facility, Openex cut the client's logistical transportation costs to zero between steps. The heavy machine bed was loaded directly onto heavy freight trucks and shipped on time to the installation site, ready for immediate OEM electrical assembly.