Page 30 - 《橡塑技术与装备》英文版2025年12月

HINA R&P TECHNOLOGY AND EQUIPMENT

industry, where there is no processing experience to draw upon. roughness is Ra1.6.
This article takes the rotor shaft of the GE1000T, the largest
internal mixer in China, as an example to study the processing
flow of the turning and milling finishing process. It explores
and analyzes the turning and milling compound machining
technology for processing large shafts by combining MAZAK
and ESPRIT, hardware and software.

1 Machine tool structure
The equipment, MAZAK E670H-6000U, boasts 7 axes,
including X, Y, Z, B, C, W, and V, and features a five-axis
Figure 2 LBB long boring bar
linkage function. Its dimensions are X1025 mm, Y670 mm,
and Z6170 mm. It is equipped with a 24" hydraulic chuck, a
center frame ranging from 350 to 700, a high-thrust center,
capable of supporting up to 7 t of load, and a high-torque, high-
performance spindle. The main spindle has a power of 45 kW,
while the milling spindle boasts 37 kW.

Figure 3 3D model of part structure

3 Processing difficulties
3.1 Dimensional control
The external cylindrical dimensional tolerance is 0.03,
the geometric tolerance for coaxiality is 0.03, the roundness
Figure 1 MAZAK machine tool structure
is 0.02, and the runout is 0.02. To effectively control various
Equipped with the LBB long boring bar system as shown dimensions and geometric tolerances, it is necessary to
in Figure 2, it utilizes a Sandvik shock-absorbing boring bar eliminate all turning steps at the clamping end in one go.
with a length of 1.8 m, an internal length of 0.5 m, and a boring 3.2 Roughness control
length of 1.3 m. The roughness of the entire shaft is Ra1.6, ensuring
uniformity, stability, and consistency of the roughness.
2 Part structure 3.3 Tool selection
The GE1000T rotor shaft, as depicted in Figure 3, The part that mates with the rotor body has a length of
is constructed from 45 steel. It has a tempered hardness 2,000 mm and a diameter of 520 mm. Since it is a mating
of HB220-260, measures 4,000 mm in length, and has a dimension, it needs to be turned in one operation. According to
maximum diameter of 520 mm. The main constituent features the high-speed turning requirements of VC250, it takes 1.5 to 2
of the part include radial elements such as an outer circle, hours, and the wear must be controlled between 0.01 and 0.02,
square slot, relief groove, circular arc slot, trapezoidal external placing extremely high demands on the cutting tool.
threads (left-hand and right-hand), metric external threads, a 3.4 Deep hole machining
D10 oil filling hole, a D60 water outlet hole, and dual key slots. D15, depth of 800 mm, 55-fold deep hole machining.
Axial features include a D15 oil filling hole, RC3/4 threads,
deep holes of D95-1.5 m and D80-2.5 m, blind holes D110 4 Process design
on both ends, M48 lifting holes, and M10 threaded holes. The The process design is shown in Table 6.

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