High-Precision Full-Servo Double-Station Upward-Pulling Internal Broaching Machine for Spline Machining

• Customization: Available
• After-sales Service: Provide
• Warranty: 1 Year
• Model NO.: FL15122
• Application: Metal
• Process Usage: Metal-Cutting CNC Machine Tools
• Movement Method: Contour Control
• Control Method: Closed-Loop Control
• Numerical Control: CNC/MNC
• Processing Precision: 0.03~0.04(mm)
• Performance Classification: High-End CNC Machine Tools
• Certification: CE, ISO 9001
• Condition: New
• Transport Package: Standard Export Package
• Trademark: UBRIGHT
• Origin: Cn
• HS Code: 8461300000
• Production Capacity: 100 Set

Product Description

Equipment Features

The FL15122 is a servo-driven double-station upward-pulling internal broaching machine with a rated pulling force of 15 tons, mainly designed for processing internal spline products (such as automotive flanges and gearbox internal gears).

 

The main body of the machine tool is made of cast iron, and the exterior is covered with 3mm high-strength sheet metal, ensuring rigidity and stability. Core components are selected from high-quality imported products: German INA heavy-duty precision roller guide rails (equipped with 4 sets of sliders per rail), German IF heavy-duty precision ball screw assemblies, INA bearings, combined with Inovance servo motors and Keyence CNC systems, achieving precise positioning and multi-stage speed broaching.

 

The equipment features the following advantages: millimeter-level precision, high efficiency of double stations, energy saving of over 80%, intelligent tool management/remote maintenance, one-key tool change/speed ratio debugging, making it an ideal choice for internal spline processing.

 

The FL15122 full-servo double-station upward-pulling internal broaching machine is a high-precision processing equipment specially designed for internal spline products (such as automotive flanges and gearbox internal gears). Its core advantages directly address the pain points of the manufacturing industry:

 

1. Millimeter-level processing accuracy, reducing the scrap rate to less than 2%;
2. Dual-station parallel processing, increasing production capacity by more than 50%;
3. Servo drive replaces the hydraulic system, achieving an energy saving rate of up to 80%;
4. Uniform-speed broaching reduces tool wear and extends tool service life by 30%;
5. 4G remote module + intelligent tool management, shortening the downtime caused by faults by 90%.

 

Whether for mass production or small-batch customization, the FL15122 can provide you with a highly efficient and low-cost solution, helping enterprises improve quality and efficiency and enhance market competitiveness.

 

 

Workpiece Basics

 

The FL15122 is mainly designed for processing internal spline workpieces, with typical applications including automotive flanges (core components of transmission systems) and gearbox internal gears.

 

Such workpieces are usually made of high-strength alloy materials and feature complex geometric structures: the internal spline tooth profile requires a precision tolerance of ±0.01 mm, and the tooth surface roughness must be ≤ Ra 1.6 μm.

 

Common risks during the machining process include: workpiece deformation caused by excessive broaching force, dimensional deviation due to rapid tool wear, thermal deformation arising from insufficient cooling, and increased scrap rates resulting from precision fluctuations of traditional hydraulic systems.

 

If these risks are not effectively controlled, they will directly increase production costs, delay order delivery, and undermine the product quality reputation.

 

Core Pain Points

Traditional hydraulic internal broaching machines have three core pain points:

 

1. Insufficient Precision: Fluctuations in hydraulic pressure lead to unstable machining accuracy, with the scrap rate as high as over 10%;
2. Low Efficiency: The single-station design fails to meet the demand for mass production, resulting in obvious production capacity bottlenecks;
3. High Cost: The continuous operation energy consumption of the hydraulic pump is 5 times that of servo-driven broaching machines. Tool wear is rapid (tool replacement frequency increases by 30%), and maintenance costs are high with slow response (equipment downtime due to faults exceeds 24 hours).

 

In addition, hydraulic broaching machines lack intelligent management functions, making it impossible to realize tool life early warning or remote maintenance, which further increases the difficulty of production management. These pain points seriously restrict enterprises' production capacity improvement and cost control.

 

Technological Process

The FL15122 follows a standardized process of blank → rough machining → finish machining → cooling → inspection:

 

1. Blank Stage: Forged or cast blanks are selected to ensure fundamental structural strength;
2. Rough Machining: Servo-driven systems rapidly remove excess material, with the broaching speed adjustable from 1-15 m/min;
3. Finish Machining: German INA roller guide rails paired with IF ball screw assemblies enable millimeter-level positioning, guaranteeing the accuracy of internal spline tooth profiles;
4. Cooling Stage: A cooling pump with a flow rate of 4 m³/h controls machining temperatures and minimizes thermal deformation;
5. Inspection Stage: Reserved automated interfaces support online measurement, enabling real-time monitoring of dimensional deviations.

 

All stages are seamlessly integrated to achieve efficient and stable processing throughout the entire workflow.

 

 

Revenue Data

 

The process value of the FL15122 is intuitively reflected through quantified indicators:

 

1. Efficiency Improvement: The double-station design increases production capacity by 55%, raising the per-shift processing volume from 130 pieces to 200 pieces;
2. Accuracy Optimization: Millimeter-level positioning accuracy ensures that the dimensional tolerance of internal splines is controlled within ±0.01 mm, reducing the scrap rate to 1.2%;
3. Cost Reduction: The servo-driven system saves 80% of energy, cutting annual electricity costs by 120,000 yuan; tool service life is extended by 30%, lowering annual tool procurement costs by 60,000 yuan;
4. Stability Enhancement: Equipment downtime caused by faults is shortened by 90%, and maintenance costs are reduced by 40%;
5. Intelligent Upgrade: 4G remote maintenance combined with tool life management improves production management efficiency by 30%.

 

These figures fully demonstrate that the FL15122 can bring significant economic benefits to enterprises.

 
 

Customer Cases

Case Study: An automotive component manufacturer needed to process 4 types of flanges with large batches but a limited budget. After adopting the FL15122, the production capacity increased by 55%, the scrap rate was reduced to 1.2%, and the annual cost was saved by 180,000 yuan.

 

 

Parameters

 

Serial No.	Parameter Name	Value	Remarks
1	Rated Tensile Force	150kN	Complies with GB/T6472
2	Maximum Stroke	1200mm	/
3	Applicable Cutter Length	800-1200mm	/
4	Number of Stations	2 Stations	Dual-station parallel operation
5	Main Slide Broaching Speed	1-15m/min	Digitally adjustable
6	Main Slide Return Speed	1-20m/min	/
7	Main Slide Hole Diameter	Φ120mm	/
8	Maximum Stroke of Auxiliary Slide	1000mm	/
9	Auxiliary Slide Tool Lifting Speed	1-20m/min	/
10	Total Equipment Power	About 35kW	/
11	Machine Mass	About 15ton	/
12	Floor Area	4200×3500×4250mm	Including pad iron height

 

Configuration

 

Serial No.	Category	Name	Brand	Remarks
1	Mechanical Part	Heavy-duty Precision Roller Guide	INA	Germany
2	Mechanical Part	Heavy-duty Precision Ball Screw Assembly	IF	Germany
3	Electrical System	PLC	Keyence	Japan
4	Electrical System	Main Servo Motor	Inovance	China
5	Electrical System	4G Remote Module	Smart IoT	Shenzhen
6	Lubrication System	Lubrication System	Bijur	France
7	Chip Removal System	Magnetic Chip Removal Machine	Jibao	Suzhou
8	Others	Proximity Switch	Omron	Japan

 

 

Are you plagued by the pain points of hydraulic screw broaching machines? The CCLC-0508-LXSF/2 Full-Servo Upward Screw Broaching Machine delivers 5 core value propositions:

Servo drive replaces hydraulic system, boosting precision by 200% (tolerance: ±0.01mm);
Dual-station parallel machining, doubling production capacity directly;
Adjustable helix angle from 0° to 30°, compatible with multi-specification internal spline screws;
Imported core components, cutting maintenance costs by 35%;
Fully automated workflow, reducing manual intervention Are you plagued by the pain points of hydraulic screw broaching machines? The CCLC-0508-LXSF/2 Full-Servo Upward Screw Broaching Machine delivers 5 core value propositions