Designed for large pipes and flanges: Advantages of DONGS horizontal turning centers

1. Break through the traditional structure and create a super rigid platform

The processing of large pipes and flanges requires extremely high load-bearing capacity and vibration resistance of the machine tool. The DONGS horizontal turning center adopts an integral bed structure based on high-strength cast iron materials. The stress distribution is optimized through finite element analysis to ensure that the machine tool can still maintain extremely low deformation error during high-speed cutting. The horizontal layout naturally lowers the center of gravity of the workpiece, and combined with the hydrostatic guide technology, the dynamic stability of the machine tool is greatly improved.

In response to the processing needs of ultra-long pipes, DONGS has designed a modular bed extension system. Users can freely combine bed sections according to the length of the workpiece, and the maximum processing length can reach more than 6 meters. With the adjustable center frame and hydraulic tailstock, fast positioning and rigid support of workpieces of different diameters can be achieved to avoid flexural deformation during processing.

2. High-torque power system to achieve efficient heavy cutting

The rough processing of flanges and large pipes often requires the removal of a large amount of excess, which poses a challenge to the torque output and continuous cutting ability of the spindle. The DONGS horizontal turning center is equipped with a high-power direct-drive spindle with a maximum torque of more than 8000 N·m. With the multi-speed speed change function, it can not only meet the torque requirements of low-speed heavy cutting, but also adapt to the speed requirements of high-speed finishing.

In addition, the dual-turret collaborative system equipped with the machine tool supports multi-tool synchronous processing. For example, when processing the flange end face, the main turret is responsible for external turning, and the auxiliary turret can perform drilling or tapping processes at the same time, which is more than 40% more efficient than the single turret. For super-large workpieces, DONGS also provides a gantry-type dual-spindle configuration. Through the synchronous drive of the two spindles, continuous processing of super-long pipes can be achieved to avoid the loss of precision caused by repeated clamping.

3. Intelligent technology empowerment, precise control of the entire processing process

In the field of precision machining, intelligent control technology is the key to improving efficiency and precision. The DONGS horizontal turning center integrates an AI adaptive control system, which dynamically adjusts the feed speed and cutting parameters by real-time monitoring of cutting force, vibration and temperature changes, extending the tool life while maximizing the processing efficiency.

For the processing of special-shaped contours of complex flanges, the machine tool is equipped with a five-axis linkage function. Through the coordinated movement of the B-axis swing head and the Y-axis offset, the precision milling of features such as inclined holes and curved surfaces can be completed. The composite processing of turning, milling and drilling can be achieved in one clamping. At the same time, the built-in online measurement system can automatically detect the workpiece size during the processing process, and feedback the data to the CNC system for compensation correction to ensure that the key dimensional tolerance is controlled within ±0.01mm.

4. Green manufacturing concept, reducing the cost of the entire life cycle

DONGS horizontal turning center also performs well in energy saving and consumption reduction. The energy recovery spindle drive system it adopts can convert the kinetic energy during the braking process into electrical energy to feed back to the power grid, which saves more than 15% energy compared with traditional models. The machine tool is also equipped with an intelligent cutting fluid management system, which reduces the consumption of cutting fluid by 30% through flow adaptive control and multi-stage filtration technology, reducing the cost of environmental protection treatment.

In terms of maintenance convenience, DONGS simplifies the disassembly and assembly process of key components through modular design. For example, the spindle unit, turret and other core modules all support quick replacement. Combined with the remote diagnosis system, the downtime maintenance time can be shortened by more than 50%, significantly improving the comprehensive utilization rate of the equipment.

V. Industry application cases: from oil and gas pipelines to wind power flanges

DONGS horizontal turning centers have demonstrated their excellent performance in many major projects at home and abroad:

Deep-sea oil and gas pipeline processing: A marine equipment company used the DONGS TCK1000- model to successfully complete the turning and flange welding groove processing of a single 6-meter-long and 0.9-meter-diameter titanium alloy pipe, shortening the construction period by 30%;