Road barrier production process with t-ribs and road barrier

Abstract

The application discloses a production process of a road guardrail with T-shaped ribs and the road guardrail, and the production process comprises the steps of laser cutting, high-temperature forming and quenching, cutting and trimming, surface treatment and laser marking. First, a steel plate is cut by laser to obtain a blank, and through high-temperature austenitizing and rapid quenching process, the tensile strength of the plate can be significantly improved, and through ultrasonic shot blasting process, the plate can be free from corrosion treatment and maintenance, and environmental pollution caused by galvanization is solved. The road guardrail produced according to the above production process comprises a plate body, the longitudinal section of the plate body is in a corrugated structure, and a plurality of rows of mounting holes are arranged at two ends of the plate body in an up-down interval. The above structure adopts the longitudinal corrugated structure, so that the bending inertia moment of the plate is increased by 2-3 times, the deformation amount is reduced by 30% under the same collision energy, the energy absorption efficiency reaches 15-20 kJ / m, the plurality of rows of mounting holes at the two ends are suitable for various types of columns, the corrugated beam thickness can be further reduced under the reinforcement of the T-shaped rib structure, and the structural strength is greatly improved.

Description

Technical Field

[0001] This invention relates to the field of road guardrail processing technology, specifically to a road guardrail production process with T-shaped ribs and a road guardrail. 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 conforming to national standards such as GB / T 31439.1-2015, the plate thickness is generally 3-4mm. Due to limitations in material strength, the thickness must be increased to meet impact resistance requirements, resulting in a unit weight of 20-30kg / m. This not only consumes a large amount of steel (over 40 tons of steel per kilometer of guardrail) 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, significant deformation upon impact (e.g., ≥300mm for Class A crash barriers), and insufficient energy absorption efficiency (<10kJ / m), failing to meet the safety requirements of high-grade highways.

[0004] Current processes rely on hot-dip galvanizing or spray coating for corrosion protection. Hot-dip galvanizing consumes a large amount of zinc ingots (approximately 5-8 kg of zinc per ton of guardrail), and the production process 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 ≥50 mg / L). This results in high treatment costs and significant 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 anti-corrosion 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 road guardrails with T-shaped ribs, which can significantly improve the structural strength of the product.

[0006] The technical solution provided by this invention is: a manufacturing process for road guardrails with T-shaped ribs, comprising the following steps: S1. Laser cutting: The steel plate is laser-cut according to the design specifications to obtain the blank; S2. High-temperature forming and quenching: The billet is heated in a roller hearth furnace to form plastic austenite, and then rapidly stamped into a corrugated plate structure using a press. At the same time, multiple T-shaped ribs are stamped on the back of the corrugated plate structure at intervals. After molding, the initial plate with martensitic structure is formed by water quenching. 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. Ultrasonic shot peening process is used to 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. At the same time, the thickness of the corrugated beam can be further reduced by the T-rib structure reinforcement.

[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 produced according to the above-described manufacturing process, comprising a plate, wherein the longitudinal cross-section of the plate has a corrugated structure, and the two ends of the plate are provided with multiple rows of mounting holes arranged vertically at intervals, and the back of the plate is stamped with a number of T-shaped ribs arranged at intervals.

[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, improving the installation efficiency by 50%. The thermoforming process combined with the T-rib structure achieves a leap in strength, lightweight and lifespan.

[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 is a dry operation, eliminating dust pollution and reducing dust emissions by over 90% compared to traditional sandblasting. The thin design results in a lower weight per unit length for the corrugated beam, reducing transportation costs by 40%, making it particularly suitable for manual handling on mountain roads and helicopter lifting operations. Its corrosion-free properties allow it to be directly used in harsh environments such as coastal salt spray areas and industrial acid rain areas, reducing costs by 70% compared to stainless steel guardrails. The combination of thermoforming and T-rib structure achieves a leap in strength, lightweight, and lifespan, making it highly practical. 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 front view of the road guardrail produced using the process described in Example 1.

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

[0016] Reference numerals: Plate 100, Mounting hole 110, T-rib 120. 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 one of ordinary skill in the art to which this invention pertains.

[0019] Reference Figure 1-2 The present invention provides an embodiment of a road guardrail manufacturing process with T-shaped ribs, comprising the following steps: Step 1. Laser cutting: The steel plate is laser-cut according to the design specifications to obtain the blank; Step 2. High-temperature forming and quenching: The billet is heated in a roller hearth furnace to form plastic austenite, and then quickly stamped into a corrugated plate structure using a press. At the same time, multiple T-shaped ribs are stamped on the back of the corrugated plate structure. After molding, the initial plate with martensitic structure is formed by water quenching. Step 3. Cutting and trimming; the initial board material is trimmed using a laser cutting machine to smooth the edges; Step 4. Surface treatment; After the board is flattened, the surface of the board is subjected to ultrasonic shot peening to obtain the finished board. Step 5. Laser drilling: Using laser drilling equipment, holes are drilled into the finished board according to the design to obtain the final product.

[0020] In the above process, the steel plate used for processing is first cut into blanks using laser cutting. The blanks then undergo high-temperature austenitization and rapid quenching, which significantly improves the tensile strength of the plate and allows for thinner materials. Ultrasonic shot peening eliminates the need for anti-corrosion treatment and maintenance, solving the environmental pollution problem associated with galvanizing. Overall protective performance is improved by 2-5 times, and the service life reaches 25-50 years. Laser cutting technology achieves a blank dimensional accuracy of ±0.1mm, reducing the secondary trimming process required by traditional stamping. Material utilization increases from 85% to 95%, and production efficiency increases by 30%. Laser drilling achieves a positioning accuracy of ±0.05mm, ensuring the fit between the mounting holes and column bolts, improving assembly efficiency by 40%, and avoiding the misalignment problem of traditional drilling. The back of the corrugated plate also has T-shaped ribs formed by stamping. The addition of T-shaped ribs increases the elongation after fracture of the corrugated beam, ensuring that it is not less than 26%, which meets the national standard for corrugated beams. It also significantly improves the bending strength, D-value, and energy absorption rate. The same specifications and thickness meet the requirements of higher road guardrail grades.

[0021] In step 2, 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, increasing the tensile strength from 300-350MPa in the traditional process to 550-650MPa, an increase of 83%-100%.

[0022] In step 4, 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, achieving corrosion-free treatment, improving overall protective performance by 2-5 times, and extending the interval between galvanized-free maintenance by more than double. 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:

[0023] 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

[0024] like Figure 1 and Figure 2As shown, a road guardrail produced according to the above-mentioned production process includes a plate 100. The longitudinal section of the plate 100 has a corrugated structure. Multiple rows of mounting holes 110 are arranged vertically at intervals at both ends of the plate 100. Several T-shaped ribs 120 are formed by stamping on the back of the plate 100.

[0025] In production applications, the longitudinal corrugated structure of road guardrails (wavelength 200-500mm, wave height 50-80mm) increases the bending moment of inertia of the plates by 2-3 times, reduces deformation by 30% under the same collision energy, and achieves an energy absorption efficiency of 15-20kJ / m, meeting the Class A or higher anti-collision requirements of JT / T281-2018 "Highway Corrugated Beam Steel Guardrail". Multiple rows of mounting holes at both ends (hole diameter φ16-22mm, hole spacing 50-150mm) are compatible with various post types (such as round tubes and square tubes), increasing installation efficiency by 50% and enabling rapid installation in complex terrains such as mountainous areas and plains.

[0026] 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 a road guardrail with T-shaped ribs, characterized in that; Includes the following steps: S1. Laser cutting: The steel plate is laser-cut according to the design specifications to obtain the blank; S2. High-temperature forming and quenching: The billet is heated in a roller hearth furnace to form plastic austenite, and then rapidly stamped into a corrugated plate structure using a press. At the same time, multiple T-shaped ribs are stamped on the back of the corrugated plate structure at intervals. After molding, the initial plate with martensitic structure is formed by water quenching. 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 material according to the design, ultimately obtaining a corrugated beam.

2. The manufacturing process of the road guardrail with T-ribs according to claim 1, characterized in that; In S2, the heating temperature of the roller hearth furnace is 880-950℃.

3. The manufacturing process of the road guardrail with T-ribs 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; The plate (100) has a corrugated structure in its longitudinal section. Multiple rows of mounting holes (110) are arranged at intervals at both ends of the plate (100). Several T-shaped ribs (120) are formed by stamping on the back of the plate (100).

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