Technologies
The production of the “Universal” plant is equipped with its own equipment park, covering all stages of manufacturing. This allows the complete work cycle to be carried out on a single site – without external contractors.
The plant park of the enterprise is represented by modern equipment of companies TOS WARNSDORF, FERMAT, DOOSAN, HYUNDAI WIA, HAAS, KLINGELNBERG HOFLER, SODICK, REMIX, KSM-SPB, NAKAL, VISTAN, VISAS and others.
Modern equipment and its versatility, high qualification of staff and years of experience in the field of mechanical processing, heat treatment of metals, welding and assembly allows:
- Ensure high product quality, compliance with regulatory and design requirements,
- Successfully fulfill orders of own production,
- Successfully fulfill orders of any complexity within the established deadlines for enterprises of other industries,
- Successfully fulfill orders of any complexity within the established deadlines for enterprises of other industries,
- Quickly master the production of new products.
Technical capabilities of «Repair and mechanical plant "Universal»
Production
Ability to process sheet and variety rolling:
- On tape-press machines (round shape workpieces up to 600 mm in diameter, flat shape workpieces 800×600 mm);
- For the installation of thermal cutting with CNC, sheet dimensions 6000×2000 mm and thickness (for gas cutting – Smax = 160 mm, for plasma cutting – Smax = 45 mm);
- On glove cutters (cutting width up to 3200 mm, thickness
up to 20 mm).
Blacksmithing and pressure treatment
Manufacture on a steam-powered hammer with a mass of falling parts 2000 kg of GOST 7829-70 type forgings: disk with hole, disk without hole, sling with straps.
Outside diameter of the forging up to 900 mm, height up to 215 mm, mass up to 150 kg. Hot bulk stamping is carried out with a force of up to 1600 CE; the company manufactures the stamping fixture itself.
Press flex with CNC: length up to 3100 mm, sheet thickness up to 30 mm, force up to 5000 kN.
The rolling leaf is up to 3000 mm wide and 40 mm thick, with the possibility of conical production. Also carried out is the rolling of anchor anchors 26 mm long up to 1800 mm.
Mechanical Machining
The company performs turning, boring, grinding, gear cutting, and milling operations on both conventional and CNC machine tools.
Machining capabilities accommodate large-scale components up to 11,000 mm in length, 4,000 mm in diameter, and 32 tonnes in weight. Operations include the machining of cylindrical, conical, and splined profiles, as well as gear components.
Wire-cut electrical discharge machining (EDM) is also utilized for parts with dimensions up to 950 × 700 mm and a weight of up to 1 tonne.
Heat Treatment
The heat treatment facility at RUP “RMZ Universal” is equipped with modern machinery capable of performing a wide range of thermal and thermochemical treatment operations on components and assemblies used in mechanical engineering.
The technologies employed ensure that products achieve the required mechanical properties, while also enhancing their wear resistance, strength, durability, and operational reliability.
The company provides heat treatment services both for its own production needs and for external organizations.
High-frequency induction hardening
Technical capabilities:
Shaft-type components:
- maximum length — 2000 mm;
- minimum length — 150 mm;
- maximum diameter — 300 mm;
- minimum diameter — 50 mm;
- maximum gear profile module — 5;
- maximum component weight — 500 kg.
Through-hardening
Technical capabilities:
- chamber furnace: maximum diameter (or width) of the workpiece — 1300 mm;
- pit furnace: maximum diameter of the workpiece — 850 mm;
- maximum length of the workpiece — 2200 mm;
- maximum load mass for hardening — 1000 kg.
Gas Carburizing
Technical capabilities:
- maximum workpiece length — 2300 mm;
- maximum workpiece diameter — 950 mm;
- maximum load mass for quenching — 1000 kg.
Annealing, Normalizing, and High-Temperature Tempering
Processes performed:
- annealing;
- normalizing;
- high-temperature tempering;
- heat treatment of welded structures — for the relief of residual stresses.
Technical capabilities:
- maximum workpiece length — 3000 mm;
- maximum width (diameter) — 1300 mm;
- maximum height — 1200 mm;
- maximum workpiece weight — 6000 kg.
Heating in a Salt Bath
Technical capabilities:
- Part weight — up to 5 kg.
The heat treatment department at RUP “RMZ Universal” possesses the production capacity to fulfill orders of varying complexity. We offer heat treatment services for machine-building components and assemblies, catering to enterprises within the Republic of Belarus as well as international partners.
Welding Operations
The facility possesses an extensive inventory of welding equipment, categorized by welding process:
- semi-automatic gas-shielded arc welding (MIG/MAG);
- gas tungsten arc welding (TIG);
- manual metal arc welding (MMA);
- robotic gas-shielded arc welding;
- submerged arc welding (SAW);
- resistance spot welding (SW);
- thermal spraying (metallizing).
A wide range of welded joints and metal/alloy surfacing operations are performed.
A wide range of welded joints and metal/alloy surfacing operations are performed.
- high-carbon, low-alloy, thick-walled steels (such as 30, 40, 35G, 35KhGSA, 40KhNS, etc.);
- alloyed chromium-nickel steels (such as 12Kh18N10T, 12Kh18N9T, 08Kh18N10T, 20Kh23N18, etc.);
- alloyed chromium-molybdenum heat-resistant steels (such as 12Kh1MF, 12KhM, 12Kh2MFSR, etc.);
- titanium alloys (such as VT1-0, OT-4, etc.);
- nickel alloys (such as KhN32T, KhN78T, etc.);
- aluminum (such as AMg2, AMg6, etc.);
- bronze (such as BrKMTs, BrAMts, etc.).
In our view, submerged arc welding is unique, as it allows for the welding of longitudinal and circumferential seams on cylindrical shells—without the need for edge preparation or a separate root pass—by using a flux backing.
Another advanced method we employ is robotic welding, which performs welding in a shielding gas environment according to a pre-set program. This approach minimizes the need for operator intervention, thereby eliminating human error and ensuring a straight, uniform weld bead. The width and reinforcement of the weld comply with the GOST 14771-76 standard, featuring a smooth transition to the base metal.
