What are unique Russian machines capable of? Metal lathes The largest lathes

The world's largest lathe is the German WALDRICH SIEGEN (Waldrich Siegen) was delivered in 1973 in South Africa, the city of Rocherville, to the ESCOM enterprise (South African Electricity Commission). The machine is listed in the Guinness Book of Records. Weight of the largest lathe: 458.6 tons, bed length 38.4 meters, maximum workpiece weight 330 tons, maximum processing diameter: 5 meters.

The world's largest milling machine is a portal 5-axis CNC machine HSM-Modal. This high-speed machining center is a product of the German company EEW Maschinenbau. Like all other CNC machining platforms, HSM-Modal is essentially a mechanical hand with a tool that moves in three-dimensional space on commands generated by specialized CAD software. However, the overall and functional dimensions of the HSM-Modal center distinguish it from the entire mass of CNC equipment.

The working area of ​​the HSM-Modal is simply huge, its length in the X-axis is 150 meters, 9 meters in the Y-axis and 4 meters in the Z-axis. The arm of the manipulator can rotate 270 degrees, and the tool head can rotate 190 degrees. The construction of the HSM-Modal center is made of aluminum and carbon plastic, making it extremely lightweight. Despite its size, the installation consumes only 5 to 7 kW of energy per hour during operation.

The HSM-Modal center is very versatile, it all depends on the type of tool used. With HSM-Modal you can perform milling operations, sawing, grinding, cutting with a water jet, sand or a laser beam. In this case, the processing accuracy is one tenth of a millimeter.

The HSM-Modal machining center is already in use in some industrial plants. With its help, models for sand casting molds are made, something that was previously done exclusively by hand. Each shape is made with high precision and four times faster than before. In other factories, the HSM-Modal is used for the manufacture of ship hulls, and in the automotive industry it is used in the manufacture of car models in 1:1 scale.

The largest four-roll bending machine was manufactured by DAVI Promau (Italy) for the Russian leader in the production of offshore drilling platforms and structures for nuclear power plants, the Petrozavodskmash company. In the company's machine park, this is the most accurate, fast and easy-to-operate machine involved in the manufacture of parts for nuclear power plants. It began to be used in rolling sheet metal with a thickness of up to 255 mm and a sheet width of up to four meters with a minimum length of the straight section of the shell. The rolling of the sheet on the sheet benders of the series is performed in one pass without turning and re-positioning the sheet for preliminary bending. It is carried out automatically and requires a preliminary operation only for the leading edge of the sheet.

All equipment at enterprises undergoes a mandatory classification according to engine power, the time of its permissible operation and other technical characteristics. The classification of lathes for metal is carried out according to several more criteria:

• accuracy class;
• weight;
• degree of automation;
• flexibility of the production system;
• special purpose in metal processing;
• versatility or narrow focus of the unit in performing metal operations.

A variety of lathes are used for metal processing. According to the ENIMS classification, all types of lathes for metal belong to group 1. The equipment is divided into groups, there are 9 in total. Groups combine equipment designed for metal processing, according to design and purpose.

The tasks that are performed on a particular machine and the severity of the parts determine the mode in which it operates, which affects the number of automatic functions of the machine and its configuration. The breakdown of equipment into groups also depends on this.

There is no such metalworking task that cannot be performed on a lathe in manual or automatic mode. But there are also groups of auxiliary machines with limited capabilities, designed to perform a narrow range of tasks, and there are almost universal ones, such as screw cutters. Their capabilities are limited by the weight and size of the workpieces.

Group 1 includes lathes for metal:

1. single spindle automatic and semi-automatic.
2. multi-spindle automatic and semi-automatic.
3. revolving multi-spindle automatic lathes.
4. drilling and cutting;
5. carousel;
6. screw-cutting;
7. multi-cutting;
8. specialized;
9. various.

Subgroups in group 1 of turning equipment also turned out to be 9, as well as groups for classifying machine tools for metal. The types of turning work are very diverse, but it is almost impossible to do without other machines when working on metal. These include:

• drilling and boring, belonging to the 2nd group.
• grinding, polishing, finishing - 3 gr.
• combined - 4 gr.
• for processing threads and gear surfaces - 5 gr.
• milling - 6 gr.
• planing, slotting, broaching - 7 gr.
• cut - 8 gr.
• the widest group No. 9 - different. this group includes equipment for the processing of pipes and couplings, peeling units, testing, dividing, balancing.

Deciphering the designations according to the ENIMS classification of lathes for metal

Lathes have a place at the top of the table because the rest of the metal machines produce blanks for them or perform subsequent work after turning operations.

How a lathe works

The working principle of the lathe is as follows:

• the rotation of the workpiece on the machine is carried out by a spindle or faceplate, which receive rotation through a gearbox, a belt drive from an electric motor;
• the amplitude of the feed determines the speed of the caliper with fixed cutters in the cutter holder;
• regardless of the type of automation of the machine - automatic or semi-automatic, it can be with a horizontal or vertical layout. Lathes received such a classification from the position of the spindle, on which the position of the workpiece during processing depends.
• on vertical machines, metal work is carried out on heavy, wide, but not long parts.
• long workpieces with small and medium diameters are machined in a horizontal position.

The more opportunities for installing additional equipment on the machine, the wider its technological capabilities.

Schemes of popular machines

As can be seen from the diagram, screw-cutting lathes are in position 6 of group 1. But they are found more often than others due to their constant need in enterprises and experimental workshops specializing in the processing of metal parts.

Screw-cutting 16K20 is used to perform basic turning work of varying complexity. The basic model is produced in 4 variants. The difference between the machines in the distance between the centers. In various modifications, this gap can be 71, 100, 140 and 200 cm. Such a variation in the working length led to other design changes to simplify the processing of parts of the same type in weight, length or diameter. Other models were developed on the basis of 16K20. Their letter designation indicates the modernization of the base model:

1. 16K20G - with a recess in the bed.
2. 16K25 - a lightweight model designed for the manufacture of parts from blanks with a diameter of up to 50 cm. The location of the blank above the bed is horizontal.
3. 16K20P - has an increased accuracy class, thanks to special bearings.
4. 16K20F3 - with numerical control.

Video 16K20F3

On this basis, other screw-cutting models for metal processing are also created. The scheme of machines is general, but if necessary, it is supplemented with the functions necessary for the customer. On machines made on the basis of 16K20, it is possible to process metals of varying degrees of susceptibility to processing, including hardened metal. The drive power is adjustable; when working with hard alloys, the energy costs of the equipment increase.

Most metalworking operations are performed on screw-cutting lathes, in which the layout scheme has a rather complex design.

The main components of the lathe:

1. bed;
2. apron;
3. spindle (front) headstock;
4. caliper;
5. back grandma.

At first glance, there are few main parts, but to control them, the design of turning equipment has:

• the friction clutch is responsible for the rotation of the spindle;
• variators are designed to change the spindle speed;
• automatic switches;
• handles, flywheels, clamps for manual movement, fixing and turning on mechanisms.

Types of lathes differ from each other in purpose, technical characteristics, layout, etc.

Accuracy notation

The accuracy of the machines according to ENIMS is indicated in the name at the end of the abbreviation in Cyrillic letters:

• H - indicator of normal accuracy;
• P - indicates the increased accuracy of the machine;
• B - indicates high accuracy;
• A - designation of especially high accuracy;
• C - machine with super precision.

Weight classification:

• Lathes weighing up to 1 ton are considered light - (< 1 т);
• Medium units include units from 1 to 10 tons, in this category there are screw-cutting units - (1-10 tons);
• Heavy - these are the machines whose mass exceeds 10 tons - (> 10 tons);
• With a weight of over 100 tons - these are unique machines - (> 100 tons).

In brackets is given the designation that occurs in the marking of the machine.

Description of some groups of lathes

Frontal machines

Lathes are designed for the manufacture of parts up to 4 meters in diameter. The purpose of machines with such technical characteristics for turning cylindrical and conical parts on them. But also on wide blanks placed on the faceplate, other metal work can be carried out, such as cutting grooves, chamfering and much more. On the frontal machines, heavy and varied work is carried out, which leaves an imprint on its technical characteristics. compared to the frontal have a more complex design.

The working part of the windshield machine consists of:

• plates;
• caliper and its base;
• front and rear headstock;
• faceplates.

Vertical lathes

The scheme of carousel machines is a little more complicated. He has:

• bed;
• faceplate;
• Remote Control;
• a turret with several positions (for example, 5);

• vertical turret support;
• two gearboxes;
• traverses;
• side support;
• 1 or 2 racks (depending on the design and purpose):
• handwheel and side handwheel;
• cutter holder for 4 items.

On turning-and-boring machines, parts with a diameter of 2 meters or more are processed. Each of the models of vertical lathes can process workpieces of various diameters. An increase in the diameter of the workpiece by 1.26 times requires an increase in the working area of ​​the machine. 6 types of rotary machines were mass-produced, with similar technical characteristics, which could process workpieces of the following sizes:

1. 2 meters;
2. 2 m 52 cm;
3. 3 m 18 cm;
4. 5 m 4 cm;
5. 6 m 35 cm.

If it is necessary to produce parts exceeding 6.35 meters, specialized machines with unique technical characteristics are made to order. It is not difficult to calculate the required size of the working area of ​​the next model in a row; it is enough to multiply the previous value by 1.26.

Turret lathes

On turret-turning equipment, parts are made from bar blanks. On the machines, it is possible to manufacture complex-shaped parts according to an individual drawing. The classification of turret machines is carried out depending on the method of fastening the workpieces on the spindle:

1. bar;
2. cartridge.

Almost all the operations that screw-cutting lathes perform can also be performed on a turret, with the only difference being that several tools can be fixed at once in the turret of the transverse calipers, in the sequence necessary for work. Screw-cutting lathes do not have such an opportunity; all subsequent types of processing are carried out on them after changing the cutter at the end of the previous operation. You can do the work with tools one by one, and some operations can be carried out in parallel to each other.

The turrets of some machines of this type are designed so that one socket can hold several cutters at once. The stroke of each tool is limited by a stop. In addition to limiting travel, they act as a caliper gear switch. Having worked out the programmed cycle, the head rotates and in the working position sets the tool necessary for the next stage.

Part processing video

Using the example of the 1G340P scheme, it can be seen that, in terms of their layout, turret machines are the same as screw-cutting lathes. The purpose of these types of machines is similar.

Turret machines can be equipped with heads rotating in a horizontal or vertical plane. Automatic and semi-automatic machines have similar turret settings before work. In this category of turning equipment, there is also a classification according to the number of spindles in the machine design.

Due to its size, the machine is listed in the Guinness Book of Records as the largest lathe in the world. Its dimensions are impressive:

• - weight 458.6 tons,
• - hull length 38.4 meters.

Able to process workpieces weighing up to 330 tons with a processing diameter of up to 5 meters.

Equipment of German origin, In 1973, it was installed at the ESCOM enterprise (South African Electricity Commission, Rocherville, South Africa), which has been working properly for more than 30 years.

CNC HSM Modal

Another giant is the 5-axis CNC portal machine HSM-Modal, the largest milling machine in the world. Also of German origin, produced by EEW Maschinenbau.

Like all CNC models, HSM-Modal is a mechanical prototype of a hand with a tool that moves in all planes according to special commands generated by CAD software. But, unlike its counterparts, the HSM-Modal center is unmatched in terms of size and variety of functions.

Dimensions of the working part of the HSM-Modal:

• length along the X axis is 150 meters,
• along the Y axis - 9 meters,
• along the Z axis - 4 meters.

the angle of rotation of the manipulator arm is 270 degrees, and the tool head is 190 degrees.

The HSM-Modal center is made of carbon plastic and aluminum, so, despite the impressive dimensions, the design is light and ergonomic. The installation consumes only 5 to 7 kW of energy per hour.

Application

It is used not only for milling at industrial enterprises, but is a universal and multifunctional device, the function of which depends on the type of installed tool. With its help, today they grind, saw and cut blank materials with a laser beam.

With a variety of functions, a high processing accuracy of 0.1 mm is maintained.

Thanks to him, the production of casting molds has become more accurate and automated. In other industries, HSM-Modal is used to create ship hulls, life-size car models.

4 roll bending machine

The largest four-roll bending machine was designed by the Italian company DAVI Promau, for the Russian company Petrozavodskmash, the country's leader in the manufacture of structures for nuclear power plants, offshore and drilling platforms. This installation is the most accurate, operational and easy to manage among all equipment for the production of parts for nuclear power plants.

Application

Now the installation is used for rolling sheet metal with a thickness of up to 255 mm and a sheet width of up to 4 m with a minimum length of the straight section of the shell. The peculiarity is that the rolling of the sheet can be done in automatic mode in one pass in automatic mode. Preliminary adjustment is required only once for the leading edge of the sheet.

The world's largest lathe is a German WALDRICH SIEGEN(Waldrich Siegen) was delivered in 1973 in South Africa, the city of Rocherville, to the ESCOM enterprise (South African Electricity Commission). The machine is listed in the Guinness Book of Records. Weight of the largest lathe: 458.6 tons, bed length 38.4 meters, maximum workpiece weight 330 tons, maximum processing diameter: 5 meters.

The largest machines - milling

The world's largest milling machine - a portal 5-axis CNC machine - is called HSM Modal. It comes from Germany, produced by EEW Maschinenbau. HSM-Modal are used for manufacturing large turbine blades (positive and negative shapes). It can manufacture wind turbine blades that are 50m or more. The maximum longitudinal movement (X axis) on this machine can be up to 151 meters. The large HSM-Modal machines can also be used for the manufacture of ship hulls, molds and other complex products of considerable size.

Large machines HSM-Modal - equipment

Large HSM-Modal machines can be equipped with various tools: for milling, drilling, grinding, polishing; hydroabrasive, plasma and laser cutting.

Large machines HSM-Modal - features

• Feed speed up to 150 m/min - significantly higher than the feed speed of other 5-axis machines.
• Various axis movements are available: from 3 to 151 m for the X-axis (longitudinal), from 3 to 9 m for the Y-axis (transverse), and from 1.75 to 4.25 m for the Z-axis (vertical).
• The accuracy is ± 0.2 mm for the X and Y axes and ± 0.17 mm/m for the Z axis.
• The relatively low weight of the machine requires a foundation of no more than 200 mm (reinforced concrete).
• Various CAD and CAM programs are compatible with the machine.

Large machines from "NOVATOR"

Today, there are several enterprises in the world that produce heavy turning and milling machines. CJSC IG "NOVATOR" can offer you big machines from any manufacturer, the most suitable for tasks of any complexity. If you need big machines- contact our specialists!

In the days of the USSR, such a bike went. The Japanese bought a Soviet machine tool, brought it home, immediately sent all the iron for remelting, and made furniture out of wooden containers. Allegedly, for Japan, poor in ore and timber, this was an extremely profitable deal. Well, really, why else do the Japanese need our machines?

Oleg Makarov

Tales are no longer told about the current machine tool industry. It is believed that it does not exist. According to the common stereotype, the Russian economy is purely based on raw materials, our entire industry is a “screwdriver assembly”, and, of course, industrial equipment is exclusively imported.

Well, as they say, there is some truth in every joke, and stereotypes rarely arise from scratch. It is all the more joyful sometimes to find out that reality is more complicated than jokes and stereotypes. And much more optimistic. Our bus rolls slowly along the asphalt path, the edges of which crumble like a sand cake. They crumble right into muddy-beige puddles that have flooded unkempt lawns. The surrounding view is not pleasing to the eye: in Soviet factories, they didn’t really indulge in landscape design, and here traces of twenty years of decline are visible in everything. The picture is very characteristic and seen more than once.

It is difficult to think of a better way to show the cyclopean scale of the mills that the Kolomna Heavy Machine Tool Plant produced. Dozens of people on the faceplate!

From soft to hard

We are on the territory of the Kolomna Heavy Machine Tool Plant, which turned 100 this year. In the Russian Empire, they started here with horse-drawn carts, then, in Soviet times, they made cannons and, finally, they switched to machine tools. ZTS was a real giant of the Soviet industry and occupied a vast territory, which is now divided among several legal entities. In general, what happened is what usually happened to such enterprises in the years when the country was carried away by trade and finance: the plant went bankrupt. It turned out that Russian machines were not needed not only by the Japanese. And yet the centenary of the famous plant did not become a date of mourning. Slowly, step by step, here in Kolomna, and also in Sterlitamak, Ivanovo and other cities, the Russian machine tool industry is reborn.

And here's what's interesting. The people who stood at the origins of the new life of the famous Kolomna plant did not come from heavy industry. They came from the very "knowledge economy". Back in 1995, a group of students, graduate students and graduates of the Moscow "Stankin" united into a production team and began to fulfill orders from Western machine-tool companies to develop software for automated control systems. There was no question of any "heavy metal" - that was an era when programmers and "computer scientists" in general were the heroes of the day. Gradually, the field of activity and the circle of partners of the team - now it became known as ZAO Stankotekh - expanded. There was an interest not only in the creation of software for machine tools, but also in their modernization, re-equipment based on modern CNC tools. Finally, in 2011 CJSC Stankotekh came to Kolomna. The company absorbed the bankrupt enterprise SKB-ZTS LLC, created on the basis of the precision machine tool shop of the former Kolomna heavy engineering plant. On these squares with a glorious history, the "machine-technologists" began to create a new enterprise, which now not only modernizes old machines, but also produces new ones. In 2013, CJSC Stankotekh, which manages production in Kolomna, merged with the machine-tool plant in Sterlitamak (NPO Stankostroenie) into the STAN group. In October of this year, it was announced that two more machine-tool productions in Ryazan and Ivanov would join the group.

In the photo, the pipe bender performs its slow, but very delicate work. Under computer control, he creates complex three-dimensional configurations from pipes - such details are used, in particular, in rocket fuel systems. Another novelty of CJSC "Stankotekh", standing in the factory shop, is the machining center model OTsP 300, which is designed for processing large-sized parts (plates, frames, cases) made of light metal alloys and composite materials. The machine can process parts of any geometric shape from five sides without reinstallation.

Machine tools that are being built and will be built today in Kolomna are not ordinary equipment at all. A unique pipe bending machine has been manufactured and is working in the workshop, the universal rolling mill URS-3200 is being gradually embodied in metal, a machine for cutting out a waffle background is being designed. No, confectionery has nothing to do with it, and just listing the names of these machines is enough for a knowledgeable person to understand which industry needed the latest Russian machines. But first, about the Japanese.

Carousels are not for fun

The choice made by CJSC "Stankotekh" at the Kolomna ZTS (more precisely, at its part) was not at all accidental. The plant, despite its difficult and typical fate for modern times, possessed, as they say now, high-level competence (and partially retained it) in the field of creating unique super-heavy industrial equipment. In 1970, the ZTS specialists built the KU299 universal carousel machine. Its gigantic faceplate could accommodate parts with a diameter of up to 20 m and a weight of up to 560 tons. The machine was exported, becoming the most complex large machine tool ever sold by the Soviet Union abroad. The buyer was ... the Japanese company Hitachi - experts from the Land of the Rising Sun did not find anything better in the world for processing super-large parts (mainly for energy needs). Another Kolomna carousel, KU153F1, also went to Japan. An even larger machine - according to some sources, the largest in the world - was made by the Kolomna people for the Volgodonsk Atommash. The part processed on the KU466 machine can have a height of up to 5 m, a workpiece diameter of up to 22 m! Now this machine is working in China. The KU168 carousel was manufactured in 1966 to solve a unique problem: a six-meter mirror of the Large Azimuthal Telescope of the Special Astrophysical Observatory of the USSR Academy of Sciences, located in the North Caucasus, was ground on it.

Roll and cut

The new owners of Kolomna production have a hard time - they inherited not only glorious traditions, but also the consequences of decline. Work is in full swing in the workshops, machines are being built and modernized, while numerous economic and organizational problems remain on the agenda. Roofing had to be repaired in some rooms. The issue of autonomous heating and water supply for each workshop is being resolved. Negotiations are underway to return to production those factory premises that are now occupied by other firms. In one of these “foreign” workshops there is a furnace for annealing huge parts (in the furnace, the metal surface is subjected to “artificial aging” for subsequent machining). The length of the furnace is 30 m, width and height - 5 m each. Someday hands will reach the arrangement of the territory, but the main thing is that production has started.

When the machine is running, it is always noticeable. Shafts are spinning, milling cutters are buzzing, calipers are moving. But the pipe bender is an exception. His work is slow and imperceptible, like the movement of a clock hand. It can only be seen how, at the point where the pipe enters the machine, it glows red-hot. It would seem, what is the technical complexity here? Everything is simple if you need to make a primitive “knee” from a pipe. But if this pipe is, say, part of the rocket fuel system, then it will have to be bent into a very complex configuration so that it fits exactly into the dimensions of the unit. In order to get a pipe that forms a given three-dimensional figure, you need a CNC machine. Only a computer can control this slow process with precision.

The URS-3200 mill is designed for the manufacture of highly precise axisymmetric parts (cones, cylinders, shells of double curvature) by the method of combined external and internal rolling. The technology of internal and external rolling is used to obtain pipes and shells for special purposes. Its main advantage is the high accuracy of the geometric dimensions of the resulting products and the strengthening of the material during the rolling process. The layout of the mill is vertical with a three-roller stand and a mandrel fixed in the axial direction for external rolling, with a three-roller stand and a stationary die for internal rolling. On the mill, the process of both external and internal rolling can be implemented. The transition from one process to another is achieved by reconfiguring the mill and installing the appropriate tool.

Another brainchild of CJSC Stankotekh is the universal rolling mill URS-3200, which is designed for the manufacture of highly precise axially centric parts - cones, cylinders, shells of double curvature - by the method of combined external and internal rolling. 3200 is the maximum diameter in millimeters of the same cylindrical or conical part that can be created on the machine, and this is a very impressive figure. At the same time, the height of the part can reach 1 m. The mill has not yet been built, but its large-sized parts are already stored in the workshop. CJSC Stankotekh makes special bets on this machine, because its parameters have no analogues in the world. The machine works with precision precision and will create parts that have no seams. Rolling (unlike welding from a sheet) allows, due to metal compaction, to make the walls of products 20% thinner than with traditional technologies, and at the same time they can withstand much greater loads. Such equipment will find its application primarily in the aerospace industry, for example, in the construction of rocket engines and command, that is, the most critical in terms of design, parts of rockets. Previously, the domestic industry produced similar machines, but only external rolling was used there, in addition, the maximum diameter of the part reached only 2.5 m. In other words, the new equipment will raise domestic rocket science to a higher technological level.

And finally, about the waffle background, which, as already mentioned, has nothing to do with the confectionery industry. The Kolomna ZTS had experience in building machines for creating a waffle background, and today new machines with this function are already being designed at the Design Bureau of CJSC Stankotekh. The waffle background is created on parts with a curved surface to lighten the product while maintaining its strength. With the help of a milling head, the machine selects a part of the metal, leaving square recesses (cells) separated by walls on the surface. Here, high accuracy is required, since the depth of the cells and the wall thickness must have strictly specified dimensions. In addition, during processing, the product should not be deformed. To solve the last task in the new design, the processing will be carried out by milling heads from two sides at once, that is, the force of one head will be compensated by the force of the other. Simultaneous processing of the part will be carried out along 32 axes. The customer of the machine is Roskosmos.

Of course, we have listed only a few flagship projects of the renovated Kolomna production, but it is already clear from them that one of the motors for the revival of the domestic machine tool industry was the emergence of serious customers, in particular in the rocket and space industry. The unification of disparate fragments of the former Soviet industry into vertically integrated corporations (despite the controversy of certain aspects of this process) caused an ever-increasing demand for the re-equipment of enterprises with new industrial equipment. Next to the newly built machines will be modernized machines. A heavy machine is like a ship, its main parts can remain operational for decades, and individual mechanisms and, of course, the control system can be replaced with more modern ones.