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0 INTRODUCTION Generally speaking, discs with small diameters can be machined on medium and small-sized vertical lathes. If the diameters of the parts are large, large discs (rings) used in large-scale hydropower, cement and chemical equipments are used. Parts, sometimes with outer diameters of up to 10 to 15 meters, require super-large machine tools or design-specific machining equipment to process them. It is understood that in China's large-scale enterprises in the 10m diameter vertical lathe is already very rare, China's largest vertical lathe is a 15m vertical lathe produced in Germany, but for the diameter of 15m or more parts processing is almost no mature processing equipment. Importantly, due to the exceptional size and weight of the parts, transportation and handling have been extremely difficult. Therefore, it is necessary to develop a simple, practical, low-cost, easy-to-transport processing equipment to the product installation site to complete the task of circumferential turning of such parts. 1 Processing Equipment Overview Design Ideas The design of the processing equipment is different from that of a general turning machining machine. We can fix the workpiece, adjust the tool to the required size on the workpiece surface, and make a rotation around the geometric center of the workpiece. Feed a certain distance and gradually process the entire circumference of the workpiece. In this way, in the case of a small amount of cutting, the required motor power is very small, and the power it consumes is mainly used to overcome the cutting resistance and the inertia of the device itself. The requirements for processing equipment are only capable of circumferential cutting and shifting. Such processing equipment is simple in structure and easy to implement. The design requires that the processing equipment is mounted on a rotating arm that can rotate around the geometric center of the workpiece. The arm is designed to be retractable. The tool holder can be moved a certain distance in the axial direction of the workpiece to process the axial thickness of the workpiece. A variable-speed driving travel device ensures that the processing equipment rotates uniformly in the circumferential direction. The tool holder can be manually moved in a small amount in the guide rails and mounted on a disk that can rotate at a certain angle to meet the needs of the processing cone. 
Figure 1 The composition and working principle of the processing system of the equipment transmission system. The main transmission system of the processing equipment is shown in Fig. 1. 1 is an extremely large-sized disc workpiece to be processed. The radius R can be 4m or more and the thickness is 50-150mm. It is a common carbon steel welded or spliced ​​by a plurality of plates: 2 is a slewing bearing seat composed of a chassis, a mandrel, a tapered roller bearing, etc. It is bolted to the process hole on the workpiece and set on the workpiece. The geometric center position: for the arm, welded by U-shaped steel, I-shaped steel, etc., bolted to the bearing outer ring of the slewing bearing seat, the bottom of the rotating arm can be set to a number of scroll wheel frame (Figure 1 (not shown), for supporting the boom boom and transmission 6 at the right end: The main movement consists of two speed motors, two pairs of fixed gears (20/28) and II-III axles passing through the I-II axis Two pairs of slip gears (44/32, 20/56) of the slip gear (37/53, 30/60) and III-IV shaft, and the speed reduction part of the caster wheel group of the IV-V shaft (20/ 40, 25/35, 30/30) Finally, a pair of pulleys (15, 16) drives (Ø120: Ø180) provide motion and power to the drive shaft VI. There are 10 different rotation speeds (30 to 660 r/min) for the drive shaft. The drive shaft 14 (the outer layer is a wear-resistant rubber material) moves on the surface of the workpiece to overcome the cutting resistance, inertial force and friction resistance of the entire processing equipment. In circular motion, if the diameter of the drive wheel is selected, the tool can obtain the corresponding cutting speed to meet the needs of different processing conditions. The cutting feed system of the equipment is two inside and outside, which are used to process the inner and outer cylindrical surfaces, respectively. They are composed of a feed block holder 8, a spindle nut 9, a handwheel 10, a turntable 11, a tool holder 12, a turning tool, and the like. The tool holder is mounted on the turntable. After the scale on the turntable is adjusted and tightened with screws, the cylindrical or conical surface of the workpiece can be machined. Because it takes a certain distance to feed axially for a revolution, it is difficult to achieve automatic feed. Considering that the axial dimension of the machining is not large, manual manual feeding or intermittent jog feeding can be adopted. 2 the relationship between the processing equipment movement of the drive shaft speed setting Taking into account the convenience of installation and debugging of processing equipment, the transmission part of the volume and weight should not be too large, so the choice of two-speed motor power is 3/4.5kW, speed 710/1440 r/min. Main Motion Drive Route Motors {1440
710 } →I (
30/60 } → III { 44/32
20/56 } →IV { 20/40
25/35
30/30 } →
Figure 1 The composition and working principle of the processing system of the equipment transmission system. The main transmission system of the processing equipment is shown in Fig. 1. 1 is an extremely large-sized disc workpiece to be processed. The radius R can be 4m or more and the thickness is 50-150mm. It is a common carbon steel welded or spliced ​​by a plurality of plates: 2 is a slewing bearing seat composed of a chassis, a mandrel, a tapered roller bearing, etc. It is bolted to the process hole on the workpiece and set on the workpiece. The geometric center position: for the arm, welded by U-shaped steel, I-shaped steel, etc., bolted to the bearing outer ring of the slewing bearing seat, the bottom of the rotating arm can be set to a number of scroll wheel frame (Figure 1 (not shown), for supporting the boom boom and transmission 6 at the right end: The main movement consists of two speed motors, two pairs of fixed gears (20/28) and II-III axles passing through the I-II axis Two pairs of slip gears (44/32, 20/56) of the slip gear (37/53, 30/60) and III-IV shaft, and the speed reduction part of the caster wheel group of the IV-V shaft (20/ 40, 25/35, 30/30) Finally, a pair of pulleys (15, 16) drives (Ø120: Ø180) provide motion and power to the drive shaft VI. There are 10 different rotation speeds (30 to 660 r/min) for the drive shaft. The drive shaft 14 (the outer layer is a wear-resistant rubber material) moves on the surface of the workpiece to overcome the cutting resistance, inertial force and friction resistance of the entire processing equipment. In circular motion, if the diameter of the drive wheel is selected, the tool can obtain the corresponding cutting speed to meet the needs of different processing conditions. The cutting feed system of the equipment is two inside and outside, which are used to process the inner and outer cylindrical surfaces, respectively. They are composed of a feed block holder 8, a spindle nut 9, a handwheel 10, a turntable 11, a tool holder 12, a turning tool, and the like. The tool holder is mounted on the turntable. After the scale on the turntable is adjusted and tightened with screws, the cylindrical or conical surface of the workpiece can be machined. Because it takes a certain distance to feed axially for a revolution, it is difficult to achieve automatic feed. Considering that the axial dimension of the machining is not large, manual manual feeding or intermittent jog feeding can be adopted. 2 the relationship between the processing equipment movement of the drive shaft speed setting Taking into account the convenience of installation and debugging of processing equipment, the transmission part of the volume and weight should not be too large, so the choice of two-speed motor power is 3/4.5kW, speed 710/1440 r/min. Main Motion Drive Route Motors {1440
710 } →I (
20
28)→II { 37/53 30/60 } → III { 44/32
20/56 } →IV { 20/40
25/35
30/30 } →
Ø120
Ø180 V (drive shaft) The rotational speed of the main shaft of the drive shaft is the main movement balance type n main = n electric iuI-IIuII-IIIuIII-IV (1) The ten speed (r/min) of the drive shaft can be calculated as: 30, respectively. 40, 60, 80, 120, 170, 230, 325, 470, 660. In order to facilitate the use, in practice, the position of each stage of the gears corresponding to the rotation speed of each drive shaft and the ratio of the hanging gears can be made into a selection table for use during processing. The setting of cutting speed The driving speed of the driving wheel is shown in Fig. 1. The driving speed of the driving wheel is: v driving = pd driving n driving (1-a) 1000 x 60 (2) Where: d driving is driving Wheel diameter (mm); n drive is the drive wheel speed (r/min); a is the frictional slip rate of the belt and the drive wheel, preferably a=0.1. Cutting speed of the turning tool After the rotation speed of the drive shaft and the diameter of the driving wheel are determined, the driving speed of the driving wheel can be calculated. The calculation formula of the machining outside circle is: v=v DRIVER R WORK -t (3) Where: R is the radius of the workpiece to be machined (mm); t is the distance (mm) between the center of the drive wheel and the machined surface of the workpiece. Note: If the inner cylindrical surface is machined, its calculation formula is: v = v drive R work R work + t' At this point t' is the distance from the inner circular processing surface to the drive wheel, about 1000mm, so that in the drive When the wheel speed is the same, the cutting speed of the inner circle machining is much smaller than that of the outer circle machining. For example, when machining an outer cylindrical surface, the drive wheel has a diameter of 150 mm, an R of 5000 mm, a t of 200 mm, and an n drive of 120 r/min, the driving speed of the driving wheel and the cutting speed of the turning tool can be calculated respectively. From formula (2), the driving speed of the driving wheel is: v driving = pd driving n driving h = p x 150 x 120 x 0.9 = 0.85 (m/s) 1000 x 60 1000 x 60 by formula (3), turning tool The cutting speed is: v = v drive R work = 0.85 × 5000 0.88 (m / s) R work-t 5000-200 Of course, if you need other cutting speeds in use, just change the speed of the drive shaft can be selected use. It should be noted that when the actual processing is performed, if the selected cutting amount is high and the power of the equipment cannot meet the requirements, the cutting speed can be reduced or the amount of the backing knife can be reduced, as long as the normal cutting requirements can be satisfied. Efficiency is not the main purpose. It is the first place to ensure the safety of people and equipment and the quality of the workpiece. Therefore, in selecting the cutting amount, it should be based on the material of the workpiece being processed, the thickness of the steel plate, the size of the diameter, and the maximum cutting force and other factors. 3 Cutting system cutting force and cutting power checking calculation Cutting force calculation can be used to calculate the initial calculation of turning force index formula, namely: Fc = CFcapXFcfYFcvZFcKFc (4) According to the general conditions of machining carbon steel, with YT15 cutter head, normal geometric angle, Medium cutting speed, available: Fc=1640apf0.84v-0.15 if take ap=4mm, f=1mm/r, available from equation (4): Fc=1640apf0.84v-0.15=1640×4×10.84×60- 0.15 = 3550 (N) Actually, the tool is manually fed 1 time in one rotation and completed within a short distance. Therefore, the cutting force is mainly determined by the amount of back-feed and the cutting speed. Calculation of cutting power and motor power The cutting power calculation formula for cutting power when turning is Pc=Fc·vc (5) If v=0.88m/s (ie n drive=120r/min), available: Pc=3550×0.88 = 3124 (W) = 3.1 (kW) Considering that the driving force of the processing equipment is to overcome the feed resistance, equipment gravity and frictional resistance, it is desirable that Pm = 1.2Pc (6) Obtainable by formula (6): Pm = 1.2 × 3.1 =3.72 (kW) The motor power is calculated by the motor power formula PE = Pm (kW) h (7) Where: h is the total efficiency of the processing equipment, take h=0.9. Available: PE = 3.72 = 4.13 (kW) 0.9 Actually, when the rotation speed is 120r/min, the motor power is 4.5kW (1440r/min), which can completely meet the machining needs when the cutting amount is not too large. In order to increase the driving force, the processing equipment can be used to drive the front and rear wheels and the drive shafts are two. There are two wheels on each shaft. The inner side is an idler wheel and only serves as a bearing. The outer side is a driving wheel. On the drive shaft, the machining equipment is driven to move along the circumference of the workpiece. The size of the driving force is related to the power of the motor, the weight of the equipment, the cutting feed resistance, the number and width of the driving wheels, the friction coefficient of the driving wheel and the workpiece, and the design should be comprehensively considered. This processing equipment can perform rough finishing on the outer and inner cylindrical surfaces of the part, and can also process chamfers, bevels, grooves, etc. near the circumference. The structural design of this processing equipment is the same as that of ordinary machine tools. Due to limitations of space, it will not be repeated here. 4 Concluding remarks The processing equipment introduced in this article is mainly applied to the processing of the circumferential surface of large-diameter discs or ring parts. It does not require special processing machine tools. The cost is low, the processing method is simple and feasible, and the installation and adjustment of the equipment are also convenient. Especially for the processing of some very large hard-to-transport disc parts, they can be adapted to local conditions, processed in situ, and have a short processing cycle, which can meet the general requirements for cylindrical processing. In addition, the structure of this processing equipment is also very simple, and ordinary machinery factories can produce and produce on their own.
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