A leaf spring is not made on one machine. It is made in six process cells, from the flat bar to the tested spring, and each cell hands its result to the next.
That is the point to remember when you plan a plant: what one cell gets wrong, the next cell cannot put right. A blank cut short stays short. Scale rolled into the surface stays there. A camber set wrong comes back as rework. The test bench only confirms the quality the other five cells built in.
So every machine in the plant is a quality machine. Here is what each cell protects in your spring.
01 · Cold working: the flats
The SPVC cell shears the flats to length, V-cuts them and punches the centre hole. R-Tech shearing automation measures each incoming flat and cuts different leaf lengths from it to a cut plan, with automatic length feed in place of manual stops. For heavy sections, the 250 T heavy-duty alligator shear cuts alloy steel up to 100 × 40 mm, with hydraulic clamping.
02 · Hot working: the profile and the eye
The leaf is formed while it is hot, and whatever is on it here is formed into it. The 300 bar water-jet descaler takes the scale off immediately before rolling. A 50 T parallelogram press corrects lateral bend directly after rolling, while the leaf is still hot, and the two-stage eye rolling machine curls Berlin and normal eyes, 180° or 270°, in flats up to 25 mm thick.
03 · Heat treatment: the camber
The spring gets its shape here: drum cambering with eight stations and central clamping, hydraulic cambering presses from 40 to 350 T built to your spring profile, and a 450 T Z-bending press that bends LH and RH air links on one machine.
04 · Assembly and finishing: the surface and the eye fit
Stress peening automation loads and unloads the leaves without manual handling. Eye milling, reaming, boring and grinding machines finish the eye, and the 18 m automatic assembly line measures load and deflection in line.
05 · Assembly benches and rework
Assembly benches, correction presses for re-cambering and bend correction, and straightening. A good plant needs this cell least; every plant needs it.
06 · Testing: the proof
The 20 T CNC servo-controlled endurance-cum-load testing machine plots the characteristic graphs of the spring with in-house software, and profile checking gauges check parabolic leaves.
Build quality in, cell by cell
Planning a new leaf spring plant, or a new cell in an existing one? Send us your spring drawing and target output, and we will engineer the machines for each cell around it.
Images for pictorial purpose only; actual machine may vary.
