TMK22130×12m Deep Hole Boring & Honing Compound Machine

1.Machine Tool Overview

1.1 Machining Range of the Machine Tool

Boring (Honing) Diameter Range: Φ100～Φ1300mm

Maximum Outer Diameter of Workpiece: Φ1600mm

Maximum Machining Depth: 12m

Maximum Workpiece Length: 12m

1.2 Machine Tool Functions

Machining Modes:

Workpiece rotation, cutter stationary, cutter feed movement

Workpiece rotation, cutter rotation, cutter feed movement

Coolant shared for boring and honing: Emulsion with a concentration of 5%–8%.

Boring Process

Emulsion is delivered to the cutter through the clearance between the oil feeder, boring bar and hole wall, then carries cutting chips out via the bottom hole of the workpiece. The cutter travels toward the headstock during machining.

Honing Process

The same emulsion coolant is adopted for honing. An independent clean oil tank is equipped for honing. The circulating pump delivers cutting fluid to the clean oil tank after paper belt filtration and magnetic roller filtration. A centrifugal pump conveys coolant to the honing head through the inner bore of the honing bar (internal oil supply). The expansion and contraction of the honing head is controlled by a servo motor, and the honing expansion-contraction unit is mounted on the rear end of the spindle in the boring bar box. For honing operation, the boring cutter, boring bar and auxiliary tooling shall be removed, then the honing cutter, honing bar and honing expansion tool assembly shall be installed, followed by hydraulic circuit switching.

1.3 Main Purpose and General Layout

This machine is specially developed for deep hole machining of cylindrical workpieces. The machine bed features high structural rigidity and stable precision retention, suitable for internal hole machining of large workpieces. It has a wide spindle speed adjustment range. The feed system is driven by AC servo motors to meet the technical requirements of various deep hole machining processes. The oil feeder realizes workpiece compression via servo drive.

1.3.1 Main Components

Machine bed, headstock, oil feeder, boring bar support, sliding guideway, rack and pinion, cooling system, PLC control system, electrical cabinet, steady rest, etc.

1.3.2 Workpiece Clamping

1.3.2.1 Closed-type Boring (Applicable for Boring Diameter ≤Φ500)

One end of the workpiece is clamped by the chuck on the headstock, the other end is tightly pressed by the cone disc on the oil feeder, and the middle section of the workpiece is supported by the steady rest. Adopt external oil supply and front chip removal machining method. Emulsion flows through the oil feeder into the gap between the boring bar and hole wall to reach the cutting edge, carries cutting chips through the workpiece bottom hole, headstock chuck and chip chute into the chip collection box.

1.3.2.2 Open-type Boring (For boring diameter over Φ500)

A pilot hole shall be pre-machined on the workpiece (finished by other machine tools). One end of the workpiece is clamped by the headstock chuck, and the other end is supported by the steady rest. The oil feeder is kept at a proper distance from the workpiece (the chip chute is arranged at this position).

Emulsion coolant flows through the rotary joint at the rear end of the spindle of the boring bar box, passes through the spindle of the boring bar box and the inner bore of the boring bar to the cutting edge. It carries cutting chips toward the headstock via the bottom hole of the workpiece, and then flows into the chip collection box through the chip chute mounted on the headstock.

1.3.3 Machine Tool Control System

Control System: PLC control system Z Servo Axis: Responsible for the longitudinal feed movement of the boring bar box. The servo motor drives the rack-and-pinion mechanism via a reduction unit. X Servo Axis: Used for servo clamping of the workpiece by the oil feeder. The servo motor drives the rack-and-pinion mechanism via a reduction unit. W Axis: Controls expansion and contraction of the honing head.

An industrial touch screen is equipped on the machine tool for operators to conduct real-time operation and status monitoring. Rotational speed, feed rate and machining depth can be preset and steplessly adjusted during machining, making the machine highly suitable for difficult-to-cut materials such as titanium alloy, stainless steel and superalloy.

The system is equipped with multiple monitoring and alarm indicators. Digital readouts are provided for the flow rate, pressure, liquid level and oil temperature of the cooling system. The operation interface is concise and user-friendly for easy operation and quick operator familiarization.

1.3.4 Basic Components (Box, Bed, Carriage etc.)

Basic components including gearbox housing, machine bed and carriage are manufactured by precision casting of high-grade cast iron. Two stress relief annealing treatments are carried out after casting to eliminate internal stress, stabilize metallographic structure and dimensional accuracy, and optimize mechanical properties.

1.3.5 Machine Bed

The machine bed is produced by resin sand casting followed by normalizing treatment. It adopts a split structure assembled with high-strength bolts and positioned by taper pins. Dual rectangular slide guides are adopted with precision grinding and high hardness on quenched guide surfaces. Total guide width: 1250 mm. A helical rack (Module 6) is installed inside the bed for cutter feed transmission; the rack undergoes precision machining and quenching to deliver excellent guiding accuracy and wear resistance. The precision rack is mounted at the middle of the bed guideways to realize feed and rapid traverse of the carriage. The machine features heavy load capacity, outstanding rigidity and stable transmission performance. V-shaped diagonal ribs are arranged inside the bed to enhance supporting rigidity and resist deformation. The outer wall of the bed directly supports the guide rails, enabling the guideways to withstand heavy cutting force with high rigidity. Deformation and chatter are effectively suppressed during machining to improve processing quality and efficiency. Apron-type guards are fitted around the perimeter of the machine bed.

1.3.6 Headstock

The headstock is fixed on the left end of the machine bed to drive workpiece rotation. It is equipped with 4 hydraulic gears with stepless speed regulation within each gear range. The motor drives spindle rotation via a coupling and gearbox. A manual chuck is mounted on the front end of the headstock for workpiece clamping. All gears are precision ground with high-frequency quenching on tooth surfaces to achieve high strength, hardness, wear resistance and fatigue limit, capable of enduring heavy alternating loads and impact loads. Circulating lubrication with lubricating oil is adopted to extend the service life of gears and bearings.

1.3.7 Boring Bar Head Assembly

This unit is mounted on the feed carriage. Contrary to the workpiece-driving headstock, it drives the cutting tool spindle rotation. It adopts four hydraulic speed stages with stepless speed adjustment within each stage. The motor drives spindle rotation through a coupling and gearbox, and a tool shank adapter is fitted at the front end of the spindle for clamping the boring bar.

All gears are precision ground, and their tooth surfaces are treated with high-frequency quenching to attain high strength, high hardness, superior wear resistance and high fatigue limit, allowing the gears to withstand heavy alternating loads and shock loads. Circulating oil lubrication is applied to prolong the service life of gears and bearings.

The boring bar head is designed with dual modes: rotary mode and fixed mode. The boring bar head can be mechanically locked when rotary motion of the boring bar is not required.

1.3.8 Closed Steady Rest

It is used for workpiece support. This closed steady rest adopts a three-point supporting structure, including two rollers at the lower part and one roller at the upper part, and each roller is equipped with a tapered roller bearing. The horizontal position of the two lower rollers can be adjusted by lead screws, while the position of the steady rest on the machine bed guideway is manually adjusted via a rack-and-pinion mechanism. Its core function is workpiece supporting.

As an auxiliary fixture for workpiece clamping, the closed steady rest is applicable to deep hole drilling of slender shafts as well as the machining of long workpieces with large outer diameters.

1.3.9 Oil Feeder (Spindle-type Structure)

It functions for cutter guiding, coolant supply and workpiece support. Driven by a servo motor for axial movement, it adapts to machining of workpieces with varying lengths and realizes clamping and unclamping of workpieces. Cooling system and hydraulic pressure gauges are mounted on the front face of the oil feeder to display real-time operating parameters during machining, helping operators judge the machining status intuitively.

Servo motor drive is adopted for workpiece clamping and releasing, featuring high precision and rigidity. The oil feeder adopts an integral box-type structure with excellent precision and structural rigidity.

With a user-friendly customized structural design, switching between drilling and boring operations can be completed merely by replacing corresponding cutters and auxiliary toolings. The oil feeder will not retreat due to excessive hydraulic pressure during drilling or boring processes.

1.3.10 Feed System

It is used to drive the cutter for axial travel. An automatic lubrication station is deployed to supply timed and quantitative lubrication for the sliding guide surfaces. A button panel is installed on the carriage, which realizes jog operation of the boring bar box spindle, forward feed, backward feed and emergency stop functions. The feed box adopts a double-gear backlash elimination structure. The input torque of the servo motor is split for output via two gears of the gear train, doubling the transmission force on the rack while eliminating transmission backlash.

1.3.11 Boring Bar Support

It supports the boring bar and restricts the movement direction of the boring bar. It is constructed as a high-rigidity monolithic structure fitted with support sleeves to absorb shocks, vibration and chatter generated during machining.

1.3.12 Cooling System

Mainly composed of cooling pumps, chip collection boxes and oil tanks, it supplies sufficient emulsion for deep hole machining. It adopts an above-ground oil tank fabricated with full welding of high-quality steel plates. Telescopic protective covers are installed between chip collection boxes on the oil tank to fully cover the tank and prevent foreign debris from falling into the coolant tank. Numerical displays for emulsion pressure, liquid level, oil temperature and flow rate are available on the operation station.

1.3.13 Electrical Control System

Key electrical components are supplied by Schneider for superior stability and reliability. This drastically reduces equipment failure rates and enhances the overall operational stability of the machine tool.

1.3.14 Machine Tool Lubrication

The sliding guide surfaces of the feed carriage are lubricated by an automatic lubrication station with fixed timing and flow rate, equipped with a low-liquid-level alarm function. Bearings and gears of the headstock adopt circulating lubrication via an independent external oil tank with a low-liquid-level alarm. Bearings and gears of the boring bar box adopt circulating lubrication via a separate external oil tank, also fitted with a low-liquid-level alarm. The carriage of the oil feeder and the carriage of the boring bar support are lubricated by a manual lubrication pump.

1.3.15 Open Steady Rest

Function: workpiece support. It is equipped with two lower rollers mounted with tapered roller bearings. The transverse position of the two lower rollers is adjusted by lead screws, and the position of the steady rest on the machine bed guideway is manually adjusted through a rack-and-pinion mechanism. Its core function is workpiece supporting. As an auxiliary fixture for workpiece clamping, the open steady rest is applicable to deep hole drilling of slender shafts as well as machining of long oversized-diameter workpieces.

2. MainTechnical Parameters of the Machine Tool

Machining Range

Boring and honing machining diameter range: Φ100～Φ1300mm

Maximum machining depth: 12 meters

Applicable workpiece length range: 2m to 12m

Machine Tool Performance Parameters

Z-axis (Feed Carriage)

Feed speed range: 0.5～1000mm/min with stepless speed adjustment

Rapid traverse speed: 3000mm/min

Supporting servo motor: 48Nm / 7.5kW servo motor

X-axis (Oil Feeder Travel Axis)

Rapid traverse speed: 3m/min

Servo motor rated torque: 35Nm / 5.5kW servo motor

Headstock Assembly

Spindle rotational speed range: 2～200 revolutions per minute

Main drive motor power: 75kW servo spindle motor

Front journal diameter of main spindle: Φ500mm

Work holding chuck specification: Φ1600mm heavy-duty manual 4-jaw chuck

Boring Bar Box Unit

Spindle speed adjustment range: 3～330 revolutions per minute

Drive motor power: 55kW servo spindle motor

Front end spindle taper bore: Metric taper 140

Spindle through-hole inner diameter: Φ120mm

Closed Type Steady Rest

Workpiece clamping diameter range: Φ200mm to Φ800mm

Single steady rest bearing capacity: 25 tons

Open Type Steady Rest

Workpiece clamping diameter range: Φ500mm to Φ1600mm

Single steady rest bearing capacity: 40 tons

Boring Cooling System

Maximum working hydraulic pressure: 0.5MPa

Maximum coolant flow rate: 1200 liters per minute

Total coolant tank volume: 12000 liters

Cooling pump motor configuration: 6 sets of 5.5kW motors

General Technical Data

Vertical height from spindle centerline to the top surface of linear guideways: 1100mm

Maximum allowable outer diameter for installed boring bar: Φ320mm

Total width of machine guideways: 1250mm

Total installed power consumption of the complete machine: 180kW

Maximum workpiece bearing load of machine tool: 60 tons

Overall floor space occupation of machine tool: 40 meters × 3.8 meters

Approximate overall machine weight: 140 tons

3. Other Machine

4. Contact Me：

Email：sale@dzguanlu.com

Whatsapp:+8613853423246

Hot Tags: tmk22130×12m deep hole boring & honing compound machine, China, suppliers, manufacturers, factory, customized, price, cheap, company, cost, for sale