Design of large-sized disk parts turning and processing equipment

In the context of machining large-diameter discs or ring-shaped components, traditional vertical lathes are typically not suitable for parts with diameters exceeding 10 to 15 meters. These massive components are often used in large-scale industries such as hydropower, cement, and chemical manufacturing. Due to their immense size, transporting and handling them is extremely challenging, making on-site processing a more practical solution. In China, the availability of 10-meter vertical lathes is already rare, and even the largest vertical lathe in the country was imported from Germany, with a diameter of 15 meters. However, for parts larger than 15 meters, there remains a lack of mature and reliable processing equipment. To address this challenge, a simple, cost-effective, and transportable machining system has been developed. This system enables circumferential turning operations directly at the installation site, eliminating the need for expensive and specialized machine tools. The design focuses on a rotating arm that can be mounted around the geometric center of the workpiece, allowing for precise tool positioning and movement. The arm is retractable, enabling axial movement of the tool holder to accommodate varying thicknesses of the workpiece. The main transmission system consists of two-speed motors, multiple gear pairs, and a drive shaft that provides motion and power to the system. With a range of ten different rotational speeds (from 30 to 660 rpm), the system allows flexibility in cutting speed and feed rate. The drive wheel, which rotates on the surface of the workpiece, ensures smooth operation while overcoming cutting resistance and friction. Manual feeding is used due to the relatively small axial dimensions involved, making the system easy to operate and maintain. The cutting force and power requirements are calculated based on the material properties, cutting parameters, and workpiece dimensions. For example, using a 150 mm diameter drive wheel and a workpiece radius of 5000 mm, the cutting speed can be adjusted accordingly. Safety and quality remain the top priorities, ensuring that the system operates within acceptable limits even under varying conditions. This equipment is capable of performing rough and finish machining on both outer and inner cylindrical surfaces, as well as chamfers, bevels, and grooves. Its simple structure makes it easy to manufacture and install, suitable for production in ordinary mechanical workshops. Overall, this system offers an efficient, practical, and economical solution for machining large, difficult-to-transport disc components.

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