Rail transit manufacturing industry

Overview of

Scenarios

The reliability requirements for thin-walled profile connections in rail transit vehicles are very high, and the traditional welding heat affected zone affects the fatigue life of the structure. The Ruiyi RUIYI hot melt drilling solution completes the hole and liner forming on the thin-walled profile of the vehicle body in one go, and forms a high-strength threaded connection with an extrusion tap to avoid welding heat effects and meet the connection requirements of rail transit structural components.

Applicable scenarios: body structural components, interior pipe connections, and assembly of thin-walled profiles for rail transit.

Industry pain points

The reliability requirements for thin-walled profile connections of vehicle bodies are very high. Traditional welding heat affected zones affect the fatigue life of structures → Fatigue cracks are prone to occur in the heat affected zone, affecting structural safety.

Large structural components have strict requirements for one-time qualification → high repair costs.

Thin walled pipes require polishing after traditional welding, resulting in multiple processes and low efficiency.

Quantification effect

Lining thickness: 3-5 times that of the original board (wall thickness 2-10mm rail transit profile).

Connection strength: tested through fatigue testing (based on testing data from similar projects in the industry).

Single hole processing time: 3-8 seconds (aperture M6-M20, wall thickness 2-10mm).

Process reduction: Replace drilling and welding with two processes (one-time molding, no need for subsequent polishing).

Comprehensive cost: reduced by about 30-40% (compared to traditional drilling and welding processes).

Tool life: capable of processing 1000-3000 holes (typical working conditions, used with hot melt paste).

Product Configuration

Core Processing Tool: Ruiyi RUIYI Hot Melt Drill - Made of hard alloy material, capable of forming holes and liners in 2-6 seconds.

Supporting materials: Extrusion tap - extruded high-strength thread.

Supporting materials: Tapping oil - extreme pressure anti-wear, improves thread quality.

Process services: scheme design and technical support - providing customized parameter schemes based on workpiece material, wall thickness, and aperture.

Technical services: on-site debugging and operation training - on-site guidance from the engineering team.

Hot melt drilling process description

Ruiyi RUIYI hot melt drilling processing advantages

No chips - the thread can withstand tension and torque, and the processing process does not require the removal of waste materials.

has high forming accuracy - it has high forming accuracy on the convex platform and stable hole position accuracy.

Strong adaptability - suitable for various tapping machines, can be adapted to manual bench drills, ordinary drilling machines, milling machines, and CNC machining centers.

High efficiency and longevity - high speed and long lifespan, improving production.

has a wide range of materials - suitable for various materials that can be hot-melt drilled, including ordinary steel, stainless steel, aluminum, copper, and other ductile metals.

Hot melt drilling process

Preparation: Ensure the power is turned on, preheat the hot melt drill bit for about 5-10 minutes, and prepare the cutting tools and auxiliary tools.

Select drill bit: Choose the appropriate hot-melt drill bit specification based on the material and thickness of the workpiece being processed. Short drills are used for workpieces below 2.5mm, and long drills are used for workpieces above 2.5mm.

Marking and positioning: Use a height ruler to mark the cross centerline of the hole position, and use a vernier caliper or steel ruler to inspect.

Drilling: When manually feeding, maintain a regular and uniform feeding speed without stopping; Quickly release the handle when the bottom of the drill bit reaches the surface of the workpiece.

Post drilling treatment: Immediately remove the hot melt drill bit after drilling is completed to prevent the drill bit from getting stuck or breaking due to cooling shrinkage of the hole.

Usage precautions: Hot melt drill bits are made of hard alloy and are prone to breakage. Be careful when using them and do not drop them on the ground or strike the drill bit with any object. Use hot melt paste specifically designed for hot melt drill bits for lubrication, instead of traditional coolant.

Hot melt drill materials and parameters

Hot melt drills are suitable for ductile metal materials such as low carbon steel, stainless steel, aluminum, copper, titanium, etc., and can also be used to process electroplated workpieces. Zinc and tin materials cannot be used. When processing stainless steel, the diameter of the hot melt drill should be increased by 0.1mm and the drilling speed should be reduced by 15% for thread holes M6 and above. When processing aluminum or other non-ferrous metals, increase the drilling speed by 50%.