Project Overview
This project involved the manufacture of a heavy-duty screw flight assembly for industrial material handling equipment used by a customer in Malaysia.
Unlike a conventional screw flight with constant dimensions, this component was designed with variable pitch together with gradually changing inner and outer diameters. The complete assembly therefore formed a tapered three-dimensional structure that became smaller along its length.
The screw flight was manufactured according to the customer’s drawing and dimensional requirements. Production required careful calculation of the developed blade dimensions, forming sequence, section alignment, welding position, and final rotating center.
For custom steel components requiring plate cutting, heavy forming, welding fixtures, dimensional control, machining, and inspection according to complex drawings, explore our custom precision metal parts manufacturing capabilities.
Product Characteristics
This screw flight had several features that made it significantly more difficult to manufacture than a standard helicoid screw flight:
- Variable pitch along the screw axis
- Changing outer diameter
- Changing inner diameter
- Tapered overall geometry
- 50 mm steel plate thickness
- Three-section welded construction
- One-set sample quantity
A conventional screw flight is normally defined by four main parameters: outer diameter, inner diameter, pitch, and plate thickness. In this project, the outer diameter, inner diameter, and pitch all changed along the length of the component.
The combination of continuously changing dimensions and unusually thick steel plate created substantial challenges during calculation, forming, handling, alignment, and welding.
50 mm Heavy Steel Plate Forming
The screw flight sections were manufactured from 50 mm thick steel plate. The heavy plate thickness increased the required forming force, material springback, handling difficulty, and risk of dimensional deviation.
Because the component had changing pitch and changing diameters, the technicians could not rely on a conventional constant screw-flight forming method. Each section had to be gradually formed and repeatedly checked against the calculated dimensions.
Experienced manual adjustment was important during production. The technicians controlled the blade curvature step by step according to the developed dimensions and the actual response of the steel during forming.
Sample Production Planning
The order quantity was one sample set. Because the component was large, heavy, and costly to rework, the production team reviewed the developed dimensions, forming sequence, welding arrangement, and fixture design before fabrication started.
Careful preparation helped reduce material waste and minimize the risk of repeated forming or correction of the 50 mm steel plate.
Three-Section Fabrication
The complete screw flight assembly was divided into three sections for forming and fabrication.
Each section had different pitch and diameter dimensions. The transition between adjoining sections therefore had to remain continuous after assembly, without creating an obvious step, misalignment, or sudden change in the blade profile.
Before welding, the three formed sections were positioned and checked according to the confirmed axial dimensions, pitch transition, inner diameter, outer diameter, and rotational center.
Welding Fixture and Center Alignment
A dedicated welding fixture was prepared to maintain the position of the three sections during assembly.
The fixture helped control the rotating center, axial alignment, section position, and continuity of the tapered screw flight while welding was completed.
The technicians also used static balance checking to locate and verify the center position before final welding and dimensional correction.
Welding Fixture and Center Alignment
A dedicated welding fixture was prepared to maintain the position of the three sections during assembly.
The fixture helped control the rotating center, axial alignment, section position, and continuity of the tapered screw flight while welding was completed.
The technicians also used static balance checking to locate and verify the center position before final welding and dimensional correction.
Dimensional and Visual Inspection
The completed screw flight assembly was checked according to the customer’s approved drawing and production requirements.
Inspection focused on the overall length, section connection, pitch transition, inner and outer diameter changes, tapered profile, rotating center, weld position, and general surface condition.
The three sections were also checked for alignment and continuity before the sample was approved for packing and delivery.
Project Result
The three screw flight sections were successfully formed, aligned, and welded into one tapered assembly with changing pitch, inner diameter, and outer diameter.
The dedicated fixture and static balance checking supported center alignment throughout fabrication. The completed sample demonstrated our ability to manufacture heavy-duty screw flight components with complex three-dimensional geometry from thick steel plate.
This project required close coordination between engineering calculation, plate cutting, heavy forming, manual correction, section alignment, fixture design, welding, and dimensional inspection.
Custom Fabricated Parts for Industrial Equipment
Complex industrial components often require more than one manufacturing process. This project combined engineering calculation, heavy plate forming, welding fixture development, section assembly, and dimensional inspection.
For OEM projects involving fabricated steel components together with machined parts, castings, forgings, fasteners, coatings, or complete industrial assemblies, explore our broader custom industrial parts manufacturing capabilities.
Related Screw Flight Manufacturing Capability
For additional screw flight types, dimensions, materials, and manufacturing examples, visit our helicoid screw flighting manufacturing page.
