For fluid equipment manufacturers in industries such as oil drilling, chemical engineering, and sewage treatment, the processing efficiency, precision, and cost of screw pump rotors directly determine market competitiveness. The PH50-1000 CNC Whirling Milling Machine centers on providing "turnkey solutions", breaks through the bottlenecks of traditional processing technologies, and delivers three core values to customers:
✓
Over 30x Higher Processing Efficiency: Single rotor machining time is drastically reduced from 4-6 hours to just 8 minutes
✓
Stable Compliance with Precision Standards: Surface finish reaches Ra1.6, and positioning accuracy ≤ 0.015 mm
✓
Significant Reduction in Unit Cost: Over 50% decrease in equipment occupancy, labor, and energy consumption costs
The PH50-1000 CNC Whirling Milling Machine is a high-efficiency processing device specially designed for precision helical components such as screw pump rotors, lead screws, and rollers. The whole machine adopts an integrated high-strength bed and double-guide rail structure, featuring high rigidity and excellent wear resistance; the 55° dovetail guide rail ensures high positioning accuracy with no crawling during low-speed feeding; precision ball screw drive, servo-driven spindle equipped with variable tooth thickness worm gear pair (adjustable backlash); the whirling milling head is powered by a high-power variable frequency motor with synchronous belt drive; the tailstock enables automatic feeding for convenient loading and unloading. Core Advantages: Over 30x efficiency improvement, stable precision of Ra1.6, and 60% cost reduction.
Application: As a core component for fluid transfer, the screw pump rotor forms sealed chambers in conjunction with stators to convey media such as crude oil, slurry, and corrosive fluids. It is widely used in oil drilling/production, chemical engineering, and sewage treatment sectors.
Material & Geometric Features: Manufactured from stainless steel, corrosion-resistant alloys, and wear-resistant alloys; features a complex helical surface requiring tight tolerances (≤ 0.01 mm); compatible with workpieces up to 700 mm in length.
Common Risks: Traditional processing methods are prone to workpiece deformation, rough surface finish, and precision deviation; characterized by low efficiency (4-6 hours per unit) and poor consistency (15% defect rate), failing to meet mass production requirements.
Pain Point 1: Extremely Low Efficiency of Traditional Processing
- Efficiency Impact: Production cycle extended by over 300%, resulting in delayed order delivery
- Cost Impact: Additional labor and energy costs of RMB 200 per rotor
- Quality Impact: 15% defect rate caused by prolonged processing time
Pain Point 2: Unstable Processing Precision
- Efficiency Impact: 2 extra hours of rework time per unit
- Cost Impact: Rework cost of RMB 150 per rotor
- Quality Impact: 8% scrap rate due to precision deviation
Pain Point 3: High Equipment Maintenance Costs
- Efficiency Impact: 10 hours of monthly downtime for maintenance
- Cost Impact: Monthly maintenance expenses of RMB 5,000
- Quality Impact: 5% defect rate caused by equipment failures
Complete Processing Chain: Blank Preparation → Rough Machining → Whirling Milling Finishing (Core Step: PH50-1000) → Surface Treatment → Quality Inspection
The PH50-1000 serves as the core process, achieving high-precision machining of helical surfaces through 4-axis linkage whirling milling, which directly determines product precision and efficiency. All steps are closely integrated: blanks undergo material testing, rough machining provides the base dimensions for whirling milling, surface treatment optimizes finish, and quality inspection ensures compliance with standards.
Blank Preparation
- Practices: Select alloy materials based on application scenarios (e.g., corrosion-resistant alloys for oil industry) + forging/casting
- Parameters: N/A
- Risks & Control: Material inhomogeneity → Inspection with a spectrometer
- Equipment: Spectrometer
Rough Machining
- Practices: Turning outer circle/end face to basic dimensions
- Parameters: Rotating speed 500-800 rpm, feed rate 0.2 mm/r
- Risks & Control: Workpiece deformation → Secure clamping with a three-jaw chuck
- Equipment: Conventional lathe
Whirling Milling Finishing (Core Process)
- Practices: 4-axis linkage whirling milling of helical surfaces
- Parameters: Rotating speed 1000-1500 rpm, feed rate 0.1 mm/r
- Risks & Control: Surface burning → High-pressure cooling + variable frequency speed regulation
- Equipment: PH50-1000 CNC Whirling Milling Machine
Surface Treatment
- Practices: Automated polishing/plating (customized by application scenario)
- Parameters: N/A
- Risks & Control: Degraded surface finish → Use of precision polishing machine
- Equipment: Precision polishing machine
Quality Inspection
- Practices: Dimensional measurement + surface finish testing
- Parameters: N/A
- Risks & Control: Missed defects → Coordinate measuring machine (CMM) inspection
- Equipment: Coordinate measuring machine
| Indicator |
Traditional Process |
PH50-1000 Solution |
Improvement |
| Single Unit Processing Time |
4-6h |
8min |
Efficiency increased by 30x+ |
| Surface Roughness |
Ra3.2 |
Ra1.6 |
Improved by 50% |
| Unit Processing Cost |
¥300/unit |
¥120/unit |
Reduced by 60% |
Scenario A: Cost Reduction & Efficiency Improvement for Mass Production
- Process Package: Blank → Rough Turning → Whirling Milling → Polishing → Inspection; Equipment: 2×PH50-1000 + Conventional Lathe + Polishing Machine; Tools: Special Whirling Milling Cutter + Three-Jaw Chuck; Parameters: Rotating speed 1200 rpm, feed rate 0.1 mm/r; Quality Control: Sampling inspection every 10 units
- Comparison: Daily production capacity increased from 10 to 300 units, with 60% cost reduction
Scenario B: Rapid Delivery for Small-Batch Production
- Process Package: Blank → Whirling Milling → Inspection; Equipment: PH50-1000; Tools: Quick-Clamping Chuck; Parameters: Rotating speed 1500 rpm; Quality Control: 100% inspection
- Comparison: Delivery lead time reduced from 2 days to 4 hours
Scenario C: Machining of Corrosion-Resistant Alloy Rotors
- Process Package: Blank → Rough Turning → Whirling Milling (PCD Tools) → Plating → Inspection; Equipment: PH50-1000 + Plating Equipment; Tools: PCD Corrosion-Resistant Cutters; Parameters: Rotating speed 1000 rpm; Quality Control: Material composition testing + dimensional measurement
- Comparison: Defect rate reduced from 15% to 2%
Parameters and Configuration
| Parameter Name |
Value / Specification |
| Equipment Model |
PH50-1000 |
| Machine Axes |
4-axis, 3-linkage (A/C/X/Z) |
| Controller |
Siemens 808 / SYNTEC / DF |
| Servo Motor / Drive |
Siemens |
| Maximum Processing Length |
700mm |
| Maximum Spindle Speed |
0-1500rpm |
| Rapid Traverse Speed (X/Z) |
4-5m/min |
| Linear Positioning Accuracy |
≤0.015mm |
| Rotary Positioning Accuracy |
≤5 arcseconds |
| Total Power |
18kW |
| Machine Dimensions |
2900×2000×2100mm |
| Machine Weight |
2800kg |
| Configuration Item |
Details |
| CNC System |
Siemens 808 |
| Servo System |
Siemens Servo Motor + Drive |
| Electrical Brand |
|
| Chip Removal Method |
Air-blow Chip Removal |
| Chuck Specification |
10-inch 3-jaw Self-centering Chuck (with dedicated mandrel) |
| Whirling Milling Head |
High-power Variable Frequency Motor + Synchronous Belt Drive |
| Tailstock Feed |
Automatic Feed + Hydraulic Locking |
| Guide Lubrication |
Centralized Intermittent Dedicated Lubrication Pump |
FAQ
Q1: How to avoid surface burning when machining rotors via whirling milling?
A: Adopt the PH50-1000's high-pressure cooling system and variable frequency speed regulation, control rotating speed at 1000-1500 rpm with a feed rate of 0.1 mm/r, reducing burning rate from 15% to below 2%.
Q2: What rotor materials is the PH50-1000 suitable for?
A: Compatible with stainless steel, corrosion-resistant alloys, and wear-resistant alloys. Customized tooling solutions are available based on materials, e.g., PCD corrosion-resistant cutters for chemical engineering applications, ensuring stable machining precision.
Q3: What is the maintenance cycle of the PH50-1000?
A: The guide rail lubrication adopts an automatic intermittent supply system. The overall maintenance cycle is 6 months, with each maintenance session taking ≤ 2 hours and monthly maintenance costs ≤ RMB 1,000.
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