Design of large-sized disk parts turning and processing equipment
In the field of machining, discs with small diameters can typically be processed using medium or small vertical lathes. However, when dealing with large-diameter parts—such as large rings used in hydropower, cement, and chemical equipment—the need for specialized machinery becomes apparent. Some components may have outer diameters reaching up to 10 to 15 meters, which necessitates the use of super-large machine tools or custom-designed equipment. In China, the availability of 10-meter vertical lathes is already limited, and for parts larger than 15 meters, there is still a lack of mature processing solutions. Additionally, due to their massive size and weight, transporting these parts poses significant challenges. Therefore, it is crucial to develop a simple, practical, low-cost, and easily transportable machining system that can be brought directly to the installation site to perform circumferential turning operations.
The design of this processing equipment differs from traditional lathes. Instead of rotating the workpiece, the workpiece is fixed, and the tool is adjusted to the required position on the surface. The tool then rotates around the geometric center of the workpiece. As the tool feeds a certain distance, it gradually processes the entire circumference. This method requires minimal cutting power, as most of the energy is used to overcome cutting resistance and the inertia of the device itself. The primary functions of the equipment are circumferential cutting and axial movement. Its structure is straightforward, making it easy to implement.
The equipment is mounted on a rotating arm that can pivot around the workpiece's geometric center. The arm is retractable, allowing the tool holder to move axially along the workpiece to process its thickness. A variable-speed drive ensures smooth rotation during the cutting process. The tool holder can be manually adjusted along guide rails and mounted on a rotating disk to accommodate conical surfaces.
As shown in Figure 1, the main transmission system consists of two speed motors, multiple gear pairs, and a drive shaft. The drive shaft has ten different rotational speeds ranging from 30 to 660 r/min, allowing flexibility in various machining conditions. The driving wheel's diameter and speed determine the cutting speed, ensuring adaptability to different materials and thicknesses.
For cutting force and power calculations, the formula Fc = CFcapXFcfYFcvZFcKFc is used. Based on standard carbon steel machining conditions, the calculated cutting force is approximately 3550 N. The corresponding cutting power is about 3.1 kW, and with a safety factor, the motor power requirement is around 4.13 kW. When operating at 120 r/min, a 4.5 kW motor is sufficient for most applications.
This equipment is capable of rough and finish machining on both inner and outer cylindrical surfaces, as well as chamfers, bevels, and grooves near the edge. Its design is similar to conventional machine tools but is optimized for simplicity and ease of use. Due to space constraints, detailed structural descriptions are not included here.
In conclusion, this processing equipment is ideal for machining large-diameter disc or ring parts. It eliminates the need for specialized machine tools, reduces costs, and simplifies the machining process. It is particularly useful for handling large, hard-to-transport components, enabling on-site processing and shortening the overall cycle time. Its simple structure makes it feasible for production in ordinary machinery factories, offering a practical solution for challenging industrial applications.
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