With stable and strong cutting force, DONGS CNC can handle large shaft parts with ease
In heavy industry manufacturing sites, large shaft parts are everywhere - wind turbine main shafts, oil drill collars, marine transmission shafts, engineering machinery drive shafts, etc., are the "backbone" of modern high-end equipment. However, this kind of complex workpiece with long length, low rigidity and thick machining allowance has always been a "hard bone" in the machining workshop: large cutting vibration, poor dimensional consistency, low processing efficiency, and even frequent rework and scrapping due to insufficient equipment rigidity.
Faced with this severe challenge, Shandong DONGS CNC Equipment Co., Ltd. focuses on the core technology of "heavy-duty cutting" and launches a high-rigidity horizontal turning center for large shaft processing. With stable and strong cutting force and excellent system coordination capabilities, it helps users easily cope with the efficient and high-precision processing of long shaft workpieces.
一、Why is large shaft processing so difficult?
The processing of shaft workpieces is not only a matter of "large size", but also a comprehensive test of the comprehensive performance of the equipment:
The structural rigidity must be strong enough:Long shafts are prone to slight bending or vibration during machining, and must rely on the machine tool to provide strong and stable support.
Powerful spindle power:In the face of rough processing requirements with large cutting depth and large feed, the machine tool must have strong low-speed torque output capability.
The tooling and tailstock must be stably matched:Unstable support will lead to processing vibration and taper deviation, affecting the overall coaxiality and surface quality.
Thermal stability must be excellent:During the long processing time, the thermal deformation of the equipment cannot be controlled, so it is necessary to ensure that the first and last pieces are equally accurate.
On traditional machine tools, shaft processing often requires segmented processing or multiple alignments, resulting in long processing cycles, unstable precision, and heavy reliance on operating experience.
二、The breakthrough of DONGS CNC horizontal turning center
DONGS has been engaged in medium and large-scale horizontal turning equipment for many years. Facing the special challenges of shaft processing, it has created a number of exclusive optimization solutions
1. High rigidity integrated bed structure
The bed of the DONGS equipment is made of high-strength cast iron, and the multi-layer rib structure design effectively suppresses vibration and distortion, which is particularly suitable for long-axis heavy cutting conditions. The widened and thickened guide rail layout further improves the feed stability of the tool holder, and can maintain rigidity even when the workpiece is under partial load.
2. Large-aperture, high-torque spindle system
In order to meet the heavy cutting needs of large shafts, DONGS is equipped with a high-torque servo spindle system, which can release powerful driving force at low speed to achieve large feed, high load, and strong rough turning without interruption. The spindle through-hole diameter can reach more than 300mm, which is suitable for smooth penetration of ultra-long pipe shaft parts, and clamping is more time-saving and labor-saving.
3. High-precision hydraulic tailstock and stable tool rest configuration
Equipped with a programmable tailstock + a stable heavy-duty tool rest, it provides strong support for long axis processing. The tailstock can be flexibly adjusted, and the tail top adopts a high-precision live top structure to effectively reduce the deflection and deformation of shaft workpieces. The multi-point support design ensures dimensional consistency and good surface quality under long-term cutting.
4. Intelligent temperature control and efficient chip removal system
Through heat source distribution simulation optimization, the DONGS machine tool structure has taken thermal stability control into consideration during the design phase, and added cooling circulation and spindle constant temperature systems to ensure long-term stable accuracy of the equipment. At the same time, the chip removal system adopts a large-flow chain plate structure to effectively deal with the large amount of chips generated during shaft processing, ensuring the cleanliness of the work area and smooth operation.
三、Customer Testimony: Wind Turbine Shaft Processing Efficiency Increased by Two Times
A European wind power core component manufacturer has long faced the problem of long processing cycle and high scrap rate of spindles longer than 4 meters. After introducing the DONGS medium and large horizontal turning center, the process that originally required two processes (rough turning + fine turning) was integrated into one clamping.
通With the stable tailstock support and strong cutting force, the customer's processing cycle was shortened from 6 hours to 3 hours, and the single-piece qualified rate was increased to more than 98%. The operator said: "DONGS's equipment is like a 'calm beast', which is stable and can be controlled. It works fast and is not afraid of mistakes.”
四、Create a reliable productivity tool for "shaft processing"
For heavy manufacturing customers who pursue efficiency and yield, a truly reliable large-scale turning equipment must not only be able to "work", but also "work well and for a long time". DONGS CNC insists on taking structural design as the basis, system optimization as the means, and user process requirements as the guide, continuously iterating equipment performance, and providing a stronger, smarter, and more stable overall solution for shaft processing scenarios.
The processing challenge of large shaft parts is not only a competition of hardware performance, but also a concentrated reflection of the collaborative efficiency of the manufacturing system. DONGS CNC has proved with its actions that stable and strong cutting force is not just talk, but a powerful expression of the deep integration of engineering capabilities and user processes.
In the future, whether it is a longer spindle, thicker shoulder, or higher production line beat requirements, DONGS will use its stable strength to help manufacturing companies to be at ease and unhindered.