一．Core manufacturing process
1.Spindle manufacturing process
Materials and heat treatment: high-quality forged steel is used, and multiple heat treatment processes such as normalizing, quenching and tempering, and high-frequency quenching are used to ensure high rigidity and wear resistance.
Precision machining: After semi-finishing, high-frequency quenching and precision grinding, combined with dynamic balance test, to ensure spindle accuracy (roundness≤0.002mm) and low noise.
Bearing assembly: high-precision ZWZ bearing group (domestic) is selected, and constant temperature workshop assembly is used to reduce the impact of thermal deformation.
2.Guide rail and bed manufacturing process
Material treatment: The bed guide rail is made of special hard material, hardened by high-frequency quenching (hardness ≥ HRC50), super hard and wear-resistant.
Precision grinding: The guide rail surface is scraped by hand or CNC grinding to ensure straightness (≤0.01mm/m) and fitting accuracy.
3.Transmission system technology
Ball screw: PDC2506-P3 and PDC4008-P3 precision screws (domestic Wanrun brand) are used in the X/Z direction, with bearings imported from Japan (Wuxi two-axis agent), preloaded assembly to eliminate clearance.
Constant temperature machining: The lead screw and nut are ground and assembled in the constant temperature workshop (20±1°C) to ensure the repeatability of positioning (±0.003mm).
4.Chuck and tailstock technology
Chuck: K11 series three-jaw chuck (produced in Wafangdian), short cylindrical connection, adjustable forward and reverse jaws, dynamic balance test adapted to high speed (≤1600rpm).
Tailstock: sleeve bore taper No. 5 Morse taper, manual locking structure, with precision bearings to ensure coaxiality (≤0.02mm).
二、Key process highlights
High-frequency quenching technology: applied to core components such as spindles and guide rails, significantly improving wear resistance and service life.
Constant temperature assembly environment: ensure that precision parts such as lead screws and spindles are assembled under the condition of no thermal deformation.
Modular design: For example, the electric turret (4 stations, 25×25mm blade) and lubrication system (RBCLB-3ZK automatic pump) adopt standardized modules for easy maintenance.
三、Quality control measures
Dynamic balance test: The spindle and chuck are dynamically balanced to avoid high-speed rotation vibration.
Accuracy detection: use laser interferometer to detect the straightness of the guide rail, and ballbar to verify the geometric accuracy of the machine tool.
Localization substitution: The core components (such as guide rails and lead screws) adopt domestic high-quality brands (Wanrun, ZWZ) to reduce costs and ensure performance.
四、Summary of Process Advantages
JW-CK6165 has achieved high rigidity, high precision (minimum setting unit 0.001mm) and excellent precision retention through material optimization (die forged steel, hard guide rails), precise heat treatment (quenching and tempering, quenching), constant temperature assembly and strict inspection. It is suitable for processing complex shaft and disc parts and has outstanding cost performance (with a domestic production rate of over 90%).