Boring Processing And Equipment PPT

Boring processing and equipment PPT

Boring processing is like performing a precise surgical operation on metal parts. When the processing accuracy reaches one-tenth of the diameter of a human hair, the success or failure of this operation directly determines whether the engine can operate stably and whether the aircraft can fly safely. Being proficient in this core technology means moving from ordinary workers to high-end manufacturing experts for practitioners in the machinery industry.

Why boring has become the core of precision manufacturing

The key value of bore machining is that it can correct the deviations left by other machining methods. In 2023, a military industrial enterprise in Shenyang introduced a five-axis boring machine from Germany. The processing accuracy of its gun barrel rifling increased from 0.02 mm to less than 0.005 mm. This improvement in accuracy directly produces a qualitative change in the accuracy of weapon shooting.

Another major advantage of bore cutting is that it can solve the problems caused by deep hole processing. There is a certain hydraulic parts factory in Suzhou. Last year, it received a batch of orders for 3-meter-long cylinders. It was impossible for ordinary drilling machines to straighten the inner holes. Later, they used the BTA deep hole boring process, and the inner hole straightness was controlled within 0.03 mm, and the yield rate suddenly increased from 60% to 98%.

Practical choices of four mainstream boring machines

Horizontal boring machines are standard configurations in heavy industry workshops. Luoyang Mining Machinery Factory uses the W200G horizontal boring machine produced in the Czech Republic to process the market supply and demand for boring large gear boxes with a diameter of 2 meters. Multi-faceted boring can be completed in one clamping, and the processing time is reduced from 8 hours to 3.5 hours.

Vertical boring machines have an irreplaceable position in precision parts processing. There is a boring processing and equipment PPT in a mold factory in Zhejiang. It uses a second-hand Mitsui vertical coordinate boring machine to process punching die guide bushing holes. It has continuously processed 100 parts. The discrete value of the hole diameter has been controlled within 0.005 mm, and the equipment purchase cost was only 400,000 yuan.

The coordinate boring machine is the ancestor of the machining center. A Beijing aerospace factory has a Swiss SIP coordinate boring machine produced in 1958, which is still in use today. It is used to process the hinge holes of satellite antenna brackets. Its position accuracy can reach 0.004 mm. Compared with many new machining centers, the stability is higher.

In the processing of large parts, CNC floor boring and milling machines are becoming more and more popular. Taizhong Group newly installed the F260 CNC floor boring machine in 2024. It can process mining machinery frames with a length of 20 meters and a weight of 300 tons, and can boring out 12 bearing holes with a coaxiality of 0.02 mm at one time.

Three types of boring tools to meet different material challenges

The main tool used for processing cast iron and ordinary steel is carbide boring tool. There is a diesel engine factory in Changzhou. When processing the HT250 gray cast iron cylinder block, the method used is Zhuzhou Diamond brand CBN coated boring tool. With this operation, the initial life of the blade can only process 80 pieces per blade, which can be processed to 220 pieces, and the cost of a single piece has also dropped by 1.8 yuan.

For difficult-to-machine materials, high-speed steel boring tools are irreplaceable. For example, when the Sichuan FAW Parts Plant was processing the turbine shell of high-temperature alloy GH4169, it tried to use a variety of carbide knives, but all of them suffered edge chipping. Finally, it chose cobalt-containing high-speed steel boring tools and used low speeds to solve the work-hardening problem.

During hard machining, for the gear inner hole of HRC58-62, which is carburized and quenched by 20CrMnTi, a reducer factory in Tianjin does not use other tools, but uses ceramic boring tools for processing. This is what is actually happening in the hardened steel processing market, because after doing so, the original grinding process is omitted, and the single-piece cycle is reduced from 25 minutes to 8 minutes.

Key application cases in the aerospace and automotive fields

The processing of aircraft engine casings is a unique display of boring skills. There is an aviation company in Guizhou that uses vibration-damping boring bar technology when processing titanium alloy casings. It has an overhang ratio of 5 times the diameter. Even so, it can still cut stably, successfully solving the problem of vibration of thin-walled parts, and shortening the product delivery cycle by 40%.

The automotive powertrain production line is the main battlefield for boring. On the relevant cylinder block processing line of the Guangzhou Honda engine factory, there are 12 German Green honing machines. They cooperate with the front boring process. The cylinder bore cylindricity is controlled to a level of 0.006 mm, thus ensuring that each car will not burn oil when it reaches 100,000 kilometers.

The market supply and demand for machining and boring of wind turbine bearing seats is a test of equipment rigidity. In the machining of the 5MW wind turbine spindle bearing seat carried out by Dalian Heavy Industry, the inner hole with a diameter of 3 meters has a single side margin of 8 mm. The powerful boring method is used to complete the processing in one pass. Compared with milling, the efficiency is increased by 3 times, and the accuracy is more stable.

Intelligent greening is reshaping the processing site

Adaptive machining technology has entered the practical stage. There is a precision parts factory in Shanghai that has installed a vibration sensor on the boring machine and a real-time compensation system. When processing aviation aluminum parts, the speed feed will be automatically adjusted. The machine will not stop when switching between milling and boring. The efficiency has increased by 25% . The supply and demand situation in the boring processing market has been improved , and tool breakage has been eliminated.

The minimum quantity lubrication process greatly reduces oil mist pollution. MQL minimum quantity lubrication boring operations are implemented in the Ningbo Mold Industrial Park. The amount of cutting oil used is reduced from 20 liters per shift to 0.5 liters per shift. The PM2.5 concentration in the workshop is reduced by 90%, and workers no longer need to wear gas masks.

Boring technology upgrade direction in the next three years

What replaces multi-process flow is the composite boring process. A pump and valve company in Shandong uses a turning and boring composite machining center to drastically reduce the pump body processing process from 7 to only 2 clampings. The shortened precision chain reduces errors and extends product life by 30%.

Online measurement implements closed-loop control and is beginning to gain popularity. The boring machine with a probe purchased by Chongqing Gearbox Company can automatically perform hole diameter detection operations during the processing process, and can also compensate for tool wear. After processing 50 parts, the size difference between the first part and the last part was only 0.002 mm, almost achieving zero waste.

Looking at this, which new boring technology do you think is most likely to be used first in the industry you are in in the next three years? Feel free to share your views in the comment area and give this like a thumbs up so that more peers can see this article.