Dimensional deviations caused by deformation during the production of galvanized steel grating directly affect its installation compatibility and structural stability. A comprehensive approach is needed, encompassing raw material handling, welding processes, hot-dip galvanizing control, mold design, transportation protection, and quality inspection, to achieve precise dimensional control.
Raw material pretreatment is fundamental to reducing deformation. As the main load-bearing component of galvanized steel grating, the initial state of the flat steel directly impacts subsequent processing quality. If the flat steel has curved bends or internal stress, and is directly fixed to the mold without thorough straightening during welding, although the surface may appear flat, strong internal stress has accumulated. When subsequent processes (such as hot-dip galvanizing) apply additional stress, the release of this internal stress can cause grating deformation, leading to dimensional deviations. Therefore, the flat steel must be rigorously straightened before production, and internal stress must be eliminated through mechanical or heat treatment to ensure the raw material is in a stable state.
The precision of the welding process is crucial for controlling dimensional deviations. During welding, the intersections of the crossbars and flat steel must form a firm connection. If the weld is weak or the weld points are unevenly distributed, the local load-bearing capacity decreases, making it prone to deformation during subsequent processing or use due to uneven stress. Furthermore, if temperature and pressure are not controlled simultaneously during welding, localized deformation may occur due to differences in thermal expansion. Using automated resistance welding equipment allows for precise control of pressure and temperature, ensuring uniform and strong weld points while reducing human error and mitigating the risk of deformation from the process source.
Temperature and time control are crucial in the hot-dip galvanizing process. During hot-dip galvanizing, the steel grating needs to be immersed in high-temperature zinc liquid to form an anti-corrosion layer. However, high temperatures cause the steel to expand thermally. If the zinc liquid temperature is too high or the immersion time is too long, the steel expands excessively, resulting in uneven contraction after cooling, which can easily lead to bending or twisting deformation. Conversely, if the temperature is too low or the time is insufficient, the zinc layer adhesion will be weak, and corrosion may weaken the structure during later use, indirectly causing deformation. Therefore, strict control of the zinc bath temperature and immersion time is necessary to ensure the steel maintains dimensional stability during thermal expansion and contraction, while simultaneously forming a uniform and dense coating.
The rationality of the mold design directly affects the forming accuracy of the grating. Dimensional deviations or structural defects in the mold can lead to uneven stress on the grating during pressing, causing deformation at the edges or center. For example, edge wear of the mold may cause diagonal deviation of the grating, while inconsistent mold depth may cause longitudinal bending. Therefore, it is necessary to regularly calibrate the mold dimensions to ensure complete consistency with the design drawings, and optimize the mold structure, such as by adding reinforcing ribs or adjusting the pressing angle, to distribute pressure and reduce localized deformation.
Protective measures during transportation and storage are crucial. If galvanized steel grating is not properly secured during transportation, it may deform due to bumps or collisions, especially at the edges or weak points. Furthermore, if no dunnage or support frame is used during stacking, prolonged pressure may cause the grating to bend or twist. Therefore, specialized packaging racks must be used during transportation to fix the grating's position and prevent slippage; during storage, it must be placed horizontally and supported with wooden blocks to ensure even stress and prevent accumulated deformation.
Quality inspection and correction must be carried out throughout the entire production process. During production, the grating dimensions must be inspected in real time, using tools such as laser measuring instruments or calipers, to ensure that parameters such as length, width, and diagonals meet standards. If deformation is found, it must be corrected promptly: minor deformation can be adjusted by mechanical pressure or manual tapping; severe deformation requires rework or scrapping to prevent it from flowing into the next process. In addition, finished products must undergo sampling inspection before leaving the factory to ensure that dimensional accuracy meets usage requirements.
Production management and personnel training are long-term guarantees. Production personnel must be proficient in the operating procedures of each process, such as welding parameter settings and zinc liquid temperature control, to reduce human error. At the same time, a quality traceability system must be established to record the production parameters and test results of each batch of products, facilitating problem tracing and process optimization. Through continuous training and standardized management, production stability can be gradually improved, reducing dimensional deviations caused by deformation.
