Flange

1. High-precision uniform hole system processing

Machining Challenges:

The flange is evenly distributed bolt holes are prone to indexing errors, and the traditional drilling process leads to a cumulative deviation of > 0.05mm in hole spacing, which affects the assembly tightness.

 

Solution:

Tool technology: multi-station drilling and hinge compound tool (integrated guide drill + step reamer), with CNC rotary table indexing and positioning system.

Technical parameters: The cumulative error of hole spacing is ≤0.03mm, the hole diameter tolerance reaches IT7 level, and the processing time of a single piece is shortened to 3 minutes.

Application case: Mass production of petrochemical pipeline flanges, the bolt mandate rate has been increased to 100%, and the pass rate of leakage test has reached 99.8%.

 

2. Efficient forming of the end face sealing groove

Machining Challenges:

The surface roughness of the flange sealing groove is required to be Ra0.8μm, and the traditional milling process needs to be refined many times, which is inefficient.

 

Solution:

Tool technology: CBN mirror milling cutter + dynamic balance tool holder, integrated micro lubrication system.

Technical parameters: A single tool completes rough finishing, the surface roughness is stable up to Ra0.4μm, and the tool life is increased by 2 times.

Application case: Marine flange sealing surface processing, daily production capacity increased from 200 to 500 pieces.

 

3. High-speed processing of corrosion-resistant materials

Machining Challenges:

316L stainless steel, duplex steel and other materials are severely hardened, the tool wears out quickly, and the cost remains high.

 

Solution:

Tool technology: AlCrN nano-coated drilling and milling composite tool + high-pressure internal cooling system (pressure 20MPa).

Technical parameters: The cutting speed is increased to 150m/min, the single-edge processing capacity reaches 1200 pieces, and the comprehensive cost is reduced by 40%.

Application case: Marine platform flange processing, salt spray test passed ISO 9227 standard for 2000 hours.