CNC Deep Hole Skiving Roller Burnishing Machine TGK25Dx6000mm

TECHNICAL SPECIFICATIONS

Machine Brief:

1.1 Machine main functions:

TGK30S CNC deep hole skiving and roller burnishing machine is an ideal machine for processing deep hole parts. It integrates boring, skiving and burnishing, and is a machine specially designed for compound processing. This machine is suitable for processing various hydraulic cylinders, spindle holes, cylinder holes, and cooling holes. The accuracy of the hole size of the processed parts can reach IT7~IT9, and the surface roughness of the inner hole: Ra0.05~0.4μm.

All casting parts of the machine adopt the box-type structure design concept and optimized design through finite element analysis to make it have the characteristics of reasonable quality, high rigidity, and high precision.

All casting parts of the machine are made of high-strength cast iron and resin sand casting. All castings are normalized after casting to eliminate the internal stress generated during the casting process. After rough machining, normalizing treatment is performed again to further eliminate the internal stress generated during the casting process, and at the same time remove the processing stress generated during the rough machining, so that it has good accuracy stability.

1.2 Machine processing and chips removal method:

The machine adopts workpiece fix, cutting tool rotate and feed processing mode . The workpiece is positioned and tightened from both ends and clamped in middle .

Pneumatic SRB head : Skiving and burnishing combined tool , boring during forward and burnishing during returning , oil pressure head supply cutting oil ,the cutting chips will be removed forward through the basic hole of workpiece .

Hydraulic SRB head : Skiving and burnishing combined tool, boring and burnishing during feeding forward , oil pressure head supply cutting oil , oil pressure head supply the cutting oil, the cutting chips will be removed forward through the basic hole of workpiece .

Boring+burnishing : Push boring and burnishing , oil pressure head supply the cutting oil, discharge the cutting chips forward through the finished hole on workpiece . The push boring and burnishing are separated , this processing method is suitable for small holes which can not be processed by the combined tools.

Machine overall layout and the structure of the main components:

Sketch for reference only

Machine overall layout: Machine bed, Headstock, workpiece carrier, servo clamping device ,oil pressure head, boring box, boring bar support rest, feeding system, cooling system, CNC control system and so on.

Machine bed:

Machine is with rectangular guide rails, which have been quenched and have high wear resistance; the bed adopts a split structure, which is assembled with high-strength bolts and is positioned with tapered pins.

A high-precision ball screw pair is installed at the right end of the bed for the movement of the drill box (Z1 axis). The ball screw pair is used for the feed of the machine, which has the advantages of smooth transmission, high transmission efficiency, and high precision. It can also effectively increase the use of cutters. A trapezoidal screw pair is installed at the left end of the bed , used for oil pressure head servo tightening and rapd movement (Z2 axis). The trapezoidal screw pair have self-locking function , can prevent the oil pressure head from returning when servo tightening .

 

Install the protection cover on the outer side of the guide rail,which has excellent leak-proof performance.

2.2 Head frame :

The head frame is fixed at the left end of the bed . A cone disc and a guide sleeve are installed at the right end of the head frame . The cone disc is used for workpiece positioning and tightening, and the guide sleeve is used to support the cutting tool after machining finished.

A chips removal bucket is installed at the left end of the head frame to transfer the cutting chips and cooling oil into the chips conveyor .

2.3 Workpiece Carrier :

The workpiece carrier is used as an auxiliary support for the workpiece, making it easy to clamp the workpiece. Its working position is slightly lower than the workpiece clamping position. By rotating the handwheel to drive the reduction mechanism, the workpiece carrier can move up and down to meet the support requirements of workpieces with different outer diameters. Due to the large deceleration transmission of the gearbox, this device is relatively easy to operate.

Sketch for reference only

2.4 Servo clamping device:

The servo clamping device is used for clamping workpieces. The servo clamping device uses a servo motor and a precision planetary reducer to drive the clamping device through a bidirectional trapezoidal screw to clamp the workpiece. The servo clamping device has a self-centering function. Servo clamping has the characteristics of easy adjustment of moving speed and clamping force.

The workpiece clamping is completed after the workpiece is tightened, and the clamping sequence can be manually adjusted.

2.5 Oil pressure head:

The oil pressure head is the core component of the deep hole machine, which is used for guiding the cutting tool , supply cutting oil , supporting boring bars, and workpiece positioning and tightening. At the head of the oil pressure head, there is a cone disc, which is used for positioning and tightening the workpiece. It is combined with the workpiece at a cone angle of 60°.

The movement of the oil pressure head (Z2 axis)is completed by a trapezoidal screw pair installed at the left end of the middle of machine bed.

 

2.6 Boring box:

The boring box is fixed on the feeding carriage for driving the tool to rotate and feed. The AC servo spindle motor of boring box drives the spindle to rotate through the belt and gears. The front end of the spindle is equipped with a boring bar clamping sleeve for clamping the boring bar.

The transmission gears of the boring box is precision ground and machined. The gear tooth surface undergoes high-frequency quenching treatment, which makes the gear with high hardness, high strength, high wear resistance, and high fatigue limit, and can withstand relatively large alternating and impact loads.

In order to improve the service life of gears and bearings, independent lubricating oil circulation lubrication is adopted.

 

2.7 Feeding carriage :

The movement of the feeding carriage (Z1 axis) is driven by a ball screw pair installed at the right end of the middle of machine bed, enabling the feeding carriage to achieve rapid movement and feed motion.

2.8 Boring bar support rest:

It is used to support the boring bar, and a support sleeve is mounted on it, which can absorb the impact and vibration generated during the processing.

The boring bar support rests adopt a hook type design. When the boring box returns, the boring bar support rests are pulled to move together. When the boring bar support rests move to the set position, the hook will automatically disengage.

 

2.9Cooling system:

The main function of the cooling system is to use the circulating liquid medium to lubricate and cool the cutting area and remove the cutting chips. The cooling system composed the oil supplying system with motor pump ,can achieve the needed flow according the processing requirements.

The cooling system adopts an above-ground oil tank structure. The cooling oil reach the cutting area through oil pressure head , flow to the chips conveyor through workpiece inner hole ,after the cutting chips are taken away by chips conveyor from the cutting oil , the cutting oil will be filtered through filter mesh (rough filtering)-magnetic filter-Fine filtering, finally go to clean oil tank, repeat like this.

The coolant system is equipped with pressure, flow, liquid level, temperature sensors and display instruments, which are installed on the control panel for easy observation.

2.10 Hydraulic system:

mainly provides hydraulic power for hydraulic gear-shift of boring box, automatic tool expansion and contraction (hydraulic expansion and contraction tool) etc.

2.11 Control system:

The independent electrical cabinet has good dust-proof effect. The cabinet is equipped with air-conditioner to make the electrical components work in a suitable temperature environment, thereby increasing the service life of the components and ensuring the stability and reliability of the control system.

The control system is SIEMENS 828D , and the main low-voltage electrical components are SCHNEIDER brand.

2.11 Documents provided :

Foundation and installation plan, General machine diagram, User Manual, CNC and program manual, Electrical Schematic diagram .

Machine main parameters:

Specification			Parameters	Remark
Working capacity	Processing hole diameter range		Φ38~Φ250mm	/
	Max. processing depth		6000mm	/
	Workpiece OD range		Φ60~Φ300mm	/
	Workpiece length range		500mm~6000mm	/
Machine performance	Z1 axis (Boring box feeding)	Infeeding speed range	5~4000 mm/min	/
		Rapid speed	5000 mm/min	/
		Servo motor rated power	5.2kW	/
	Z2 axis(Oil pressure head moving)	Rapid speed	3000 mm/min	/
		Servo motor rated power	4.3kW	/
	Servo clamping device	Rotary speed range	5~200r/min	/
		Servo motor rated power	1.5KW	/
	Boring box	Rotation speed range	40~1200r/min	Two-gear, stepless
		Motor power	45kW	Servo spindle motor
	Others	Machine total power	About 125kW	/
		Machine load bearing	3T	/
Cooling system		Cooling pump motor	18.5kW	Three groups
		Circulating pump motor	2.2kW	Two groups
		Max.pressure	2.5MPa	/
		Flow adjusting range (about)	300~900 L/min	Quantitative adjust
		Filtering accuracy	50μm	/
Hydraulic system		Max. pressure	6.3MPa	/

 

Machine Main Components Manufacturer List:

No.	Name	Model/Specification	Manufacturer	Remark
1	CNC control system	828D	SIEMENS	/
2	Z1-axis servo motor	5.2kW	SIEMENS	Feeding system
3	Z2-axis servo motor	4.3kW	SIEMENS	Oil pressure head move
4	Servo motor	1.5kW	SIEMENS	Servo clamping
5	Boring box main motor	45kw	Chinese famous brand (MK)	Servo spindle motor
7	Spindle bearing		HRB,ZWZ,ZYS
8	Ball screw pair	Nominal OD Φ80	HIWIN or equal brand
9	Trapezoidal screw pair	Nominal OD Φ80	/	Self-made
10	Precision planetary reducer		FASTON	Taiwan brand
11	Rotary joint		DUBLINE	Germany
12	Coolant pump	Vane pump	Japan YUKEN
13	Paper filter	Filtering accuracy 50μm	Chinese famous brand
14	Main hydraulic components		Chinese famous brand
15	Main electric components		SIEMENS/ SCHINEIDER

List of machine parts :

No.	Name	Unit	Quantity
1	Machine bed	set	1
2	Head frame	set	1
3	Workpiece Carrier	set	2
4	Servo clamping device	set	2
5	Oil pressure head	set	1
6	Boring box	set	1
7	Boring bar support rest	set	2
8	Cooling system	set	1
9	Lubrication system	set	1
10	Hydraulic system	set	1
11	CNC system	set	1
12	Chips removal device	set	1

 

Optional device :

NO.	Name	QTY
1	Auto loading/unloading system	1SET
2	Oil chiller (YB90)	2SET
3	Oil mist separator	1SET

 

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