Efficiently process extra-long pipe flanges? High-rigidity horizontal turning center solves the problem of oil equipment manufacturing

In the fields of heavy equipment manufacturing such as petrochemicals and energy transportation, the processing of large pipes, flanges and oil pipe fittings has always faced severe challenges. These workpieces are not only large in size and over-length, but also have complex structural characteristics and strict sealing requirements, which puts extremely high demands on the rigidity, stability and process adaptability of processing equipment. Traditional processing methods often cause workpiece deformation and frequent surface defects due to insufficient equipment capacity, and horizontal turning centers, with their unique technical advantages, are becoming a key tool to solve the dilemma of super-large pipe processing.

1. Industry pain points in the processing of super-large pipe fittings

The processing difficulties of workpieces such as oil pipelines and flanges are concentrated in three aspects:

Uncontrolled clamping deformation: The dead weight of super-long pipe fittings can easily cause bending, and conventional chucks can easily cause elliptical deformation, affecting the sealing of the end face;

Inefficient composite processing: Flange end face turning, pipe body outer circle processing and weld groove processing require multiple changes, and the process connection takes a long time;

Unstable surface quality: When intermittently cutting pipeline welds, insufficient equipment rigidity can easily cause tool vibration, resulting in substandard thread accuracy and sealing groove finish.

A petrochemical equipment factory was forced to rework 3 times due to end face warping during flange processing, which directly delayed the project delivery cycle.

2. Rigidity innovation of horizontal turning center

In view of the processing characteristics of pipe fittings, the professional-level horizontal turning center reconstructs the processing logic through three core technologies:

Overall strengthening of bed structure: The inclined bed design and multi-layer reinforcement rib structure ensure that the torsional rigidity of the bed is doubled during the full-stroke processing of ultra-long pipe fittings, and the deformation caused by the drooping of the dead weight is completely eliminated;

Heavy-duty guide rail system: The X/Z axis is equipped with an ultra-wide roller guide rail, and with the two-way drive anti-backlash technology, it can maintain cutting stability even when processing oil pipelines with welds;

Dynamic compensation module: The intelligent hydraulic system senses the deformation of the workpiece in real time, automatically compensates the tool path, and ensures the coaxiality of the flange end face and the outer circle of the pipe.

3. Integrated processing solution for extra-long pipe fittings

In order to meet the demand of "one clamping to complete multiple processes" for petroleum pipe fittings, the equipment innovatively integrates multiple processes:

Modular spindle system: the chuck and the center can automatically adjust the clamping force according to the pipe diameter, and with the tailstock hydraulic locking device, it can achieve fast and accurate positioning of 5-meter-class pipe fittings;

Multi-function turret configuration: the 12-station power turret integrates turning tools, milling cutters and drilling units, and flange end face grooves, pipe body bevels, threads and other features can be processed simultaneously;

Intelligent temperature control technology: spindle circulation cooling and bed temperature compensation work together to avoid thermal errors caused by long-term processing affecting the accuracy of the sealing surface.

IV. Efficiency of petroleum equipment manufacturing has increased

In actual application, the equipment has shown significant advantages:

Quick change system: The hydraulic self-centering chuck combined with the visual centering interface reduces the clamping time of the φ2000mm flange by 70%, and the clamping accuracy is continuously stable;

Chip management solution: The fully enclosed protective cover and the high-pressure flushing device solve the problem of chip entanglement in the processing of ultra-long pipelines, and the maintenance efficiency is improved by 50%;

Process adaptive capability: The built-in special processing program library for petroleum pipe fittings can automatically match the cutting parameters of typical workpieces such as API standard flanges and ANSI pipes.