large flange processing is full of challenges how does dongs cnc help customers cope with them perfectly-0

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Large flange processing is full of challenges. How does DONGS CNC help customers cope with them perfectly?

Jun.07.2025

In the field of heavy industry manufacturing, large flanges are key connecting components and are widely used in key areas such as oil pipelines, wind power equipment, shipbuilding engineering and chemical plants. The high processing difficulty, strict precision requirements and tight production rhythm are a major technical challenge faced by many manufacturing companies. Shandong DONGS CNC Equipment Co., Ltd., with its deep understanding of industry needs and extreme polishing of technical details, is helping more and more customers to calmly cope with this challenge.

1.Three major difficulties in large flange processing

The workpiece is large and difficult to clamp
Large flanges can easily have a diameter of thousands of millimeters and weigh hundreds of kilograms or even tons. Traditional equipment is difficult to clamp stably, and any slight deviation will affect the roundness and flatness.

The processing cycle is slow and the processing process is unstable
During the entire process from rough machining to fine machining, high rigidity and stable cutting force must be maintained to avoid dimensional drift caused by thermal deformation and vibration, which places extremely high demands on the performance of the machine tool itself.

Frequent switching of multiple processes and high cost of manual intervention
Faced with multiple processes such as drilling, turning inner and outer circles, chamfering, and end face processing, traditional solutions usually require multi-machine linkage, repeated handling, and manual clamping, which is not only inefficient but also prone to errors.

 

2. How does DONGS CNC solve the flange processing dilemma?

In response to the above pain points in large flange processing, DONGS CNC has developed medium and large horizontal turning centers designed specifically for heavy parts. Through structural optimization, system integration and function expansion, it provides customers with one-stop processing solutions.

1. High rigidity structure design to achieve stable clamping and heavy-load cutting

DONGS horizontal turning center adopts high-rigidity bed formed by integral casting, and is equipped with widened guide rails and heavy-duty ball screws to ensure that the bed does not deform, the guide rails do not shake, and the cutting does not jump when processing large-sized flanges. The matching hydraulic chuck and customized tooling can easily achieve a stable fixation of the flange in one clamping.

2. High-efficiency spindle system ensures long-term stable operation

In order to cope with the long-term cutting requirements of large-diameter parts, DONGS is equipped with a high-torque, large-aperture servo spindle with strong low-speed cutting capabilities. It can achieve large feed and deep cutting in the roughing stage, and ensure delicate and stable processing in the finishing stage, truly realizing "both roughing and finishing, and both efficiency and precision".

3. Multifunctional integrated design, one clamping to complete multiple processes

DONGS's composite horizontal turning center supports power turret, face drive tool, automatic tool change system and other configurations, and can continuously complete complex processes such as turning, drilling, tapping, chamfering, etc. in one clamping. It avoids the errors and losses caused by workpiece handling and secondary clamping, and greatly improves efficiency and qualification rate.

3. Customer Case Testimony: The Transformation and Upgrading Path of Wind Power Supporting Enterprises

A world-renowned wind power equipment manufacturing company had long used traditional horizontal lathes in conjunction with vertical machining centers to complete various processes for large flanges. The processing cycle was long, the labor cost was high, and there were cumulative precision errors between processes.

Since the introduction of the DONGS horizontal turning center, the company has compressed the original four processes into one, and the whole flange processing cycle has been shortened from the original 8 hours to 3 hours. More importantly, the number of front-line operators has been reduced from 6 to 2, and the stable operation of the equipment has also greatly reduced the frequency of after-sales maintenance.

The customer said in an interview: "This equipment has enabled us to achieve real efficiency improvement and process simplification, and is a key step in the transformation of the factory.

4. Full technical service process to create a cooperative experience of "buying with confidence and using with ease"

DONGS CNC not only strives for excellence in equipment, but also pays more attention to the customer experience. From pre-sales process evaluation, to customized clamping design, on-site installation and commissioning, to training and after-sales guarantee, DONGS has established a complete service closed loop to ensure that every customer can truly "use it well, use it for a long time, and save money".

 

The processing difficulty of large flanges is not only a test of equipment performance, but also a comprehensive challenge to the manufacturer's process understanding and service capabilities. With its professional and systematic solutions, DONGS CNC is gradually becoming a trusted partner in the field of heavy-duty processing. In the future, DONGS will continue to deepen its presence in the large workpiece processing market segment and provide more customers with "efficient and reliable" China-made intelligent solutions.

 

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