What is FRP Grating Machine?
FRP Grating Machine is a specialized piece of equipment designed to manufacture FRP molded gratings (Fiberglass gratings).
1.Structural Composition
Party 1:: Mold System
The frp grating mold is the main part of the machine, which determines the shape and size(mesh size and panel size) of the frp gratings. Molds are made by material of carbon steel. The mold is designed with precise grid-like grooves to ensure that the FRP material can form the required grid structure after injection. The width, spacing and depth of these grooves can be adjusted according to customer needs.In order to facilitate the removal of the finished product from the mold, the mold block design usually includes a certain draft angle, so that the product can be easily pushed out after curing.
Party 2:: Raw Material Supply System
The raw material of FRP gratings is mainly include glass fibers yarn, resin, curing agent,color paste and filler.
the resin, curing agent,color paste and filler need to be mixed by mixer equipment before produce with the mold , the fiberglass yarn will be put on the yarn stand near to the end of mold, when start production, it will be layup to the frp grating mold block grooves by labors. also the mixed resin will be pour evenly into mold grooves together with fiberglass yarn.
Party 3:: Curing and Cooling System
During production of FRP molded gratings, the resin need to be curing and cooling, The hot water and cold water circulation system in the FRP grating equipment is a key component used to control the mold temperature, ensuring that the resin is cured at the appropriate temperature, which affects the quality and production efficiency of the product. The system helps achieve a uniform curing process and reduces product defects such as bubbles, deformation or incompletely cured areas by providing stable heating and cooling functions. for hot water system need a equipment (boiler or air source heating pump)that can heating water, for cooling water systems, need a equipment (cooling tower)that can cooling water. also need 2 pieces of water pump to make the water can circulate.
Party 4:: Injection System
The ejection system of the FRP grating mold is a key component to ensure that the finished grating can be smoothly demolded from the mold. The design and performance of this system directly affects production efficiency, product quality and the service life of the mold. the power of injection pin is provide by hydraulic pump, which is a independent equipment to buy with frp grating mold, there a 2 pieces of oil cylinder at bottom plate of frp grating mold, it can work together with hydraulic pump to provider injection power to FRP grating mold.
Party 5:: Grinding and Cutting System
After frp grating injection from the mold, the surface of grating is not uneven, with lots of resin flaky debris, so for make is smooth, it need to proceed with surface grinding machine，if the panel size is not clients request, it also need one more step that cut the size, any parts that exceed the specified size need to be trimmed and the grating cut as required. This step can be done manually or using an automated cutting device integrated into the equipment.
2.Mold Block Description
The mold block is the important party of FRP grating mold, the size and gap of block will be decide the FRP grating mesh size. the total quantity of block both horizontal and vertical line will be decide the panel size of FRP gratings, FRP grating block mold is made by material of 45# steel ( It has a higher carbon content, leading to higher hardness and strength compared to AISI SAE 1018 steel. The typical tensile strength of China 45 steel is around 600-700 MPa, while its yield strength is approximately 355 MPa )
Chemical Composition (Main component is iron, also contains few other elements below):
C: 0.42-0.50%
Si: 0.17-0.37%
Mn: 0.50-0.80%
P: ≤0.035%
S: ≤0.035%
Cr: ≤0.25%
Ni: ≤0.25%
Cu: ≤0.25%
It’s ensity is 7. 85g/cm3, elastic modulus is 210GPa, poisson ratio is 0.269.
Mechanical Property of 45# steel:
Normalizing:850℃
Quenching: 840℃
Tempering: 600℃
Tensile Strength:≥600Mpa
Yield Strength: ≥355Mpa
Elongation: 16%
Shrinkage: 40%
Impact Energy: 39J
Hardness of the delivery condition:
Hot rolled steel: ≤229HB
Annealed steel: ≤197HB
3.Demoulding System Design
Designing a demoulding system is a critical aspect of frp grating mold, focusing on how to efficiently remove frp grating from the mold after solid process. A well-designed demoulding system is essential for ensuring product quality, enhancing production efficiency, and minimizing mold maintenance costs.
1. Draft Angle (Block angle )
In mold design, a slight taper or angle is added to the mold’s block to facilitate easier ejection. Appropriate draft angle reduces friction between the part and the mold, preventing damage or deformation during ejection. The draft angle should be chosen based on height of frp gratings, such as height 38mm of frp gratings should be design different with height 30mm frp gratings.
2. Ejection Mechanism
Ejector Pins: Used to push the part directly out of the mold, suitable for products with flat bottoms.
Ejector Plate: A plate that moves to eject the entire part, ideal for larger or more complex shapes.
Hydraulic Cylinders: Provide greater force for ejection, especially for large or heavy parts.
4.Accessories Equipment
Accessories equipment is an important party of complete production line, except the main party of frp grating mold to produce frp gratings, for new start factory also need to source full set of accessories equipment to finish complete process of FRP gratings manufacture.
- Resin Mixer / Resin mixing bath
- Yarn Creel Stand
- Hydraulic Pump
- Water-circulating Pump
- Mixer Tank
- Cooling Tower
- Boiler or Air source heater pump
- Grinding machine/ polish machine
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