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Flash Removal Cylinder


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This flash removal cylinder is the core actuator of the post-weld processing system in high-speed rail flash-butt welding machines, mounted between the flash removal tool holder and the fixed frame. Immediately after upsetting, while the joint is still in a high-temperature plastic state, this cylinder drives the flash removal tool forward with great force at high speed, precisely shearing off the excess weld flash from the rail head, web, and base in a single stroke, restoring the rail surface to a smooth, flush finish. A compact short-stroke design (120 mm stroke) delivers powerful thrust from a 135 mm bore. Combined with a high-strength alloy steel barrel, a precision hard-chrome plated piston rod, multi-stage dust-proof seals, and bidirectional cushioning, it provides stable, reliable, leak-free flash removal motion under the severe conditions of high-temperature weld spatter, intense vibration, and outdoor dust — a key component ensuring the surface quality and operational safety of continuous welded high-speed rail.

Brand:
PAZON

Flash Removal Cylinder Hydraulic Cylinder Hydraulic Cylinder Rail Welding Machine

Product Description

Bore: Φ135 mm
Rod: Φ50 mm
Stroke: 120 mm (for flash removal tool advance distance)
Operating pressure: continuous 25 MPa, max 31.5 MPa
Max push force: approx. 450 kN (at 31.5 MPa, full-bore side)
Max pull force: approx. 388 kN (at 31.5 MPa, annular side, for tool retraction)
Breakaway pressure: ≤0.4 MPa
Piston velocity: <0.5 m/s (rapid flash removal response, instantaneous acceleration)
Operating frequency: intermittent heavy-duty, 1 flash removal cycle per weld
Internal leakage: ≤0.02 ml/min (at 25 MPa, over seal service life)
Temperature range: -20 ℃ to +80 ℃ (standard); -40 ℃ to +120 ℃ customizable
Suitable for: high-speed rail flash-butt welders, mobile rail welding vehicles, etc.

Features & Benefits

Powerful Rapid Flash Removal
The barrel is forged from high-yield-ratio quenched and tempered alloy steel, with welds UT/MT inspected. The large-diameter thick-walled piston rod is precision hard-chrome plated (HV900–1100), maintaining high thrust and speed against hot flash resistance to ensure clean shearing within the optimal temperature window.
High Side-Load Resistance & Guidance
Embedded wide bronze or composite guide rings with precision clearance control absorb radial forces from three-face tool loading and offset conditions, preventing rod scoring and ensuring smooth, precise flash removal action.
Multi-Stage Seals & Weld Spatter Protection
A metal scraper ring and multiple heavy-duty wipers at the gland effectively block high-temperature spatter and metal chips generated during flash removal. The main seal is a high-temperature polyurethane and filled PTFE composite, guaranteeing long-term zero external leakage in hot spatter environments.
Internal Cushioning for Noise Reduction
Progressive cushioning devices at both piston ends automatically decelerate and absorb impact energy at end strokes, eliminating rigid impacts, reducing noise, and protecting the flash removal tool holder and the cylinder itself.
Compact Maintenance-Free Design
The optimized envelope and mounting dimensions fit the welder's compact flash removal station. Self-lubricating composite bushings at all pivot points eliminate daily greasing and provide long service life under frequent outdoor operation.
Optional Smart Monitoring
A built-in displacement sensor can be integrated to provide real-time flash removal tool position feedback, supporting precise stroke monitoring and fault warning via the welder's control system.