Road guardrail corrugated beam production process and road guardrail corrugated beam

Abstract

The application discloses a production process of a road guardrail corrugated beam, which comprises the steps of laser cutting, high-temperature forming and quenching, cutting and trimming, surface treatment and laser punching, etc.; the application cancels the galvanizing process, can reduce the zinc consumption of each ton of product, avoids the discharge of galvanizing wastewater (containing heavy metals such as zinc and chromium), adopts dry operation in the ultrasonic shot blasting process, has no dust pollution, and reduces dust emission compared with the traditional sand blasting process. The thin design makes the weight of the corrugated beam per unit length lower, and the production and transportation costs are also significantly reduced, and the application is especially suitable for installation operation in mountainous areas; the anti-corrosion feature makes the corrugated beam directly used in harsh environments such as coastal salt mist areas and industrial acid rain areas, can replace the traditional stainless steel galvanized guardrail, and the application range is expanded to high-corrosion scenes which cannot be covered by the traditional process.

Description

Technical Field

[0001] This invention relates to the field of road guardrail processing technology, specifically to a production process for corrugated beams of road guardrails. Background Technology

[0002] Most road guardrails on the market are made of ordinary steel (such as Q235 steel), galvanized steel, high-strength steel, etc.

[0003] Manufactured using Q235 or Q345 steel plates, and manufactured according to national standards such as GB / T31439.1-2015, the thickness must be increased to meet impact resistance requirements due to material strength limitations. The plate thickness is generally 3-4mm, resulting in a unit weight of 20-30kg / m. This not only consumes a large amount of steel but also incurs high transportation and installation costs, making rapid deployment particularly difficult in complex terrains such as mountainous areas. Furthermore, traditional hot-rolling processes struggle to optimize the material's microstructure, resulting in a tensile strength of only 300-350MPa. This leads to significant deformation upon impact and insufficient energy absorption efficiency, failing to meet the safety requirements of high-grade highways.

[0004] In terms of corrosion protection technology, existing processes rely on hot-dip galvanizing or spray coating. Hot-dip galvanizing consumes a large amount of zinc ingots and generates wastewater containing heavy metals such as zinc and chromium (approximately 3-5 tons of wastewater are discharged per ton of galvanized parts, with a zinc ion concentration ≥50mg / L). This process is costly to treat and easily causes environmental pollution. Furthermore, the galvanized layer has a lifespan of only 8-15 years, requiring regular maintenance and recoating, increasing the total lifespan cost by 30%-50%. In corrosive environments such as coastal salt spray and industrial acid rain, traditional corrosion protection processes fail even faster, with annual maintenance costs for guardrails accounting for 10%-15% of the initial cost. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a manufacturing process for corrugated beams used in road guardrails, which can significantly improve the structural strength and corrosion resistance of the product while reducing production costs.

[0006] The technical solution provided by this invention is: a manufacturing process for corrugated beams of road guardrails, comprising the following steps: S1. Laser cutting: Laser cutting of raw steel plates according to design specifications to obtain blanks; S2. High-temperature forming and quenching: The billet is heated in a roller hearth furnace to form plastic austenite, and then rapidly stamped using a press. After forming, it is water-cooled and quenched to form the initial plate with martensitic structure. S3. Cutting and trimming: The initial sheet material is trimmed using a laser cutting machine to smooth the edges of the sheet material. S4. Surface treatment; After the board is leveled, the surface of the board is subjected to ultrasonic shot peening to obtain the finished board. S5. Laser drilling: Using laser drilling equipment to drill holes in the finished board according to the design, and finally obtain the finished product.

[0007] In this technical solution, the steel plate is first cut into blanks by laser cutting. The blanks are then subjected to high-temperature austenitization and rapid quenching processes, which can significantly improve the tensile strength of the plate and reduce the material thickness to 1.2-2.5mm, which is only half of the original national standard thickness. At the same time, the ultrasonic shot peening process can achieve corrosion-free and maintenance-free treatment, solve the environmental pollution of galvanizing, improve the comprehensive protection performance by 2-5 times, and achieve a service life of 25-50 years.

[0008] Preferably, in S2, the heating temperature of the roller hearth furnace is 880-950℃.

[0009] Preferably, in S4, the ambient temperature during ultrasonic shot peening is 80 degrees Celsius.

[0010] The present invention also provides a road guardrail corrugated beam manufactured according to the above-described manufacturing process, comprising a plate body, wherein the longitudinal cross-section of the plate body is corrugated, and multiple rows of mounting holes are provided at intervals at both ends of the plate body.

[0011] The above structure adopts a longitudinal corrugated structure, which increases the bending moment of inertia of the plate by 2-3 times, reduces the deformation by 30% under the same collision energy, and achieves an energy absorption efficiency of 15-20kJ / m. The multiple rows of mounting holes at both ends are suitable for various column types (such as round tubes and square tubes), improving the installation efficiency by 50% and enabling rapid installation in complex terrains such as mountainous areas and plains.

[0012] The beneficial effects of this invention are as follows: It eliminates the galvanizing process, reducing zinc consumption per ton of product annually and avoiding galvanizing wastewater discharge. The ultrasonic shot peening process generates no dust pollution, reducing dust emissions by over 90% compared to traditional sandblasting. The thinner design results in lower weight per unit length for the corrugated beam, reducing transportation costs and making it particularly suitable for transport in mountainous areas and helicopter lifting operations. Its corrosion-free nature allows it to be directly used in harsh environments such as coastal salt spray areas and industrial acid rain areas, significantly reducing costs compared to stainless steel guardrails and expanding its applicability to highly corrosive scenarios inaccessible to traditional processes. Attached Figure Description

[0013] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the accompanying drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.

[0014] Figure 1 This is a perspective view of the corrugated beam of the road guardrail produced by the process in Example 1.

[0015] Figure 2 This is a side view of the corrugated beam of the road guardrail produced by the process in Example 1.

[0016] Reference numerals: Plate 100, Mounting hole 110. Detailed Implementation

[0017] The embodiments of the technical solution of the present invention will now be described in detail with reference to the accompanying drawings. These embodiments are merely illustrative of the technical solution of the present invention and are therefore intended to limit the scope of protection of the present invention.

[0018] It should be noted that, unless otherwise stated, the technical or scientific terms used in this application should have the ordinary meaning as understood by those skilled in the art to which this invention pertains.

[0019] One embodiment of the present invention provides a manufacturing process for corrugated beams of road guardrails, comprising the following steps: S1. Laser cutting: Laser cutting of raw steel plates according to design specifications to obtain blanks; S2. High-temperature forming and quenching: The billet is heated in a roller hearth furnace to form plastic austenite, and then rapidly stamped using a press. After forming, it is water-cooled and quenched to form the initial plate with martensitic structure. S3. Cutting and trimming: The initial sheet material is trimmed using a laser cutting machine to smooth the edges of the sheet material. S4. Surface treatment; After the board is leveled, the surface of the board is subjected to ultrasonic shot peening to obtain the finished board. S5. Laser drilling: Using laser drilling equipment to drill holes in the finished board according to the design, and finally obtain the finished product.

[0020] In the above process, the steel plate used for processing is first cut into blanks by laser cutting. The blanks are then subjected to high-temperature austenitization and rapid quenching processes, which can significantly improve the tensile strength of the plate and reduce the material thickness to 1.2-2.5mm, which is only half of the original national standard thickness. Ultrasonic shot peening process can achieve corrosion-free and maintenance-free treatment, solve the environmental pollution of galvanizing, improve the comprehensive protection performance by 2-5 times, and achieve a service life of 25-50 years.

[0021] Laser cutting technology is used during the cutting process to achieve a blank size accuracy of ±0.1mm and a cut perpendicularity of ≤1°, reducing the secondary trimming process required by traditional stamping. Material utilization rate is increased from 85% to 95%, and production efficiency is improved by 30%. Laser drilling positioning accuracy reaches ±0.05mm, ensuring the matching accuracy between the mounting hole and the column bolt, improving assembly efficiency by 40%, and avoiding the deviation problem of traditional drilling.

[0022] In S2, the heating temperature of the roller hearth furnace is 880-950℃. Through high-temperature austenitization (880-950℃) and rapid water-cooling quenching in the roller hearth furnace, the plate forms a martensitic structure, and the tensile strength is increased from 300-350MPa in the traditional process to 550-650MPa, an increase of 83%-100%.

[0023] In S4, the ambient temperature during ultrasonic shot peening is 80 degrees Celsius. Ultrasonic shot peening at 80°C forms a high-density compressive stress layer on the surface of the sheet material, replacing the traditional galvanizing process. This eliminates the need for anti-corrosion treatment, improves overall protective performance by 2-5 times, and more than doubles the interval between galvanized-free maintenance. The above-mentioned production process allows for a reduction in material thickness to 1.2-2.5mm (only 50% of the original national standard thickness), resulting in a 50% reduction in unit weight, while maintaining the same impact resistance (such as collision protection level), achieving a lightweight innovation of "replacing thickness with thinness." The technical specifications of this process with those of the traditional galvanizing process are compared as follows:

[0024] In summary, this technology, through three-dimensional innovation in materials, processes, and structures, systematically solves the pain points of traditional guardrails being "thick, heavy, dirty, and expensive," and has significant technological leadership and market competitiveness in fields such as traffic safety, environmental protection, and industrial upgrading. Example

[0025] like Figure 1 and Figure 2 As shown, this embodiment provides a road guardrail corrugated beam produced according to the above-described manufacturing process, including a plate 100. The longitudinal section of the plate 100 has a corrugated structure, and multiple rows of mounting holes 110 are arranged vertically at intervals at both ends of the plate 100.

[0026] The longitudinal corrugated structure (wavelength 200-500mm, wave height 50-80mm) increases the bending moment of inertia of the plate by 2-3 times, reduces the deformation by 30% under the same collision energy, and achieves an energy absorption efficiency of 15-20kJ / m, meeting the anti-collision requirements of Class A or above in JT / T281-2018 "Highway Corrugated Beam Steel Guardrail".

[0027] With multiple rows of mounting holes at both ends (hole diameter φ16-22mm, hole spacing 50-150mm), it is compatible with various column types (such as round tubes and square tubes), improving installation efficiency by 50% and adapting to rapid installation in complex terrains such as mountainous areas and plains.

[0028] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention, and they should all be covered within the scope of the claims and specification of the present invention.

Claims

1. A manufacturing process for corrugated beams of road guardrails, characterized in that; Includes the following steps: S1. Laser cutting: Laser cutting of raw steel plates according to design specifications to obtain blanks; S2. High-temperature forming and quenching: The billet is heated in a roller hearth furnace to form plastic austenite, and then rapidly stamped using a press. After forming, it is water-cooled and quenched to form the initial plate with martensitic structure. S3. Cutting and trimming: The initial sheet material is trimmed using a laser cutting machine to smooth the edges of the sheet material. S4. Surface treatment; After the board is leveled, the surface of the board is subjected to ultrasonic shot peening to obtain the finished board. S5. Laser drilling: Using laser drilling equipment to drill holes in the finished board according to the design, and finally obtain the finished product.

2. The manufacturing process for corrugated beam road guardrails according to claim 1, characterized in that; In S2, the heating temperature of the roller hearth furnace is 880-950℃.

3. The manufacturing process for corrugated beams of road guardrails according to claim 1, characterized in that; In S4, the ambient temperature during ultrasonic shot peening is 80 degrees Celsius.

4. A road guardrail corrugated beam manufactured using the production process described in any one of claims 1-3, characterized in that; It includes a plate body, the longitudinal section of which has a corrugated structure, and multiple rows of mounting holes are provided at both ends of the plate body at intervals.

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