Case of Removing Tungsten Drill out of Large Workpiece
The work piece is 28mm thick, the drill ofφ18.8 was broken in that through-hole.
Luoyang Xincheng got a new task on 7th, Nov., 2015. This time, we removed a drill (material:alloy and tungsten steel) out of a work piece weighted 2 tons in Luoyang Yiming Machine Manufactory.
If the drill is only made of tungsten, it could be scraped out easily. The hard problem is that the alloy part is also broken in.
The work piece is 28mm thick, the drill ofφ18.8 was broken in that through-hole.
So, we operated with High Power SFX4000B Broken Tap Remover and set the distance of processing. Finally the hole was processed through by an electrode of φ9. The broken drill pieces were knocked off after processing.
The latest updated SFX-4000B did this job perfectly. The shining touching panel and shake head make it easier to fulfill this task.
After a smooth processing, we found that the drill had already bonding with the work piece. Those pieces could not be tapped out at all.
So we broke the structure of drill by corrosion off the three edges.
All the broken drills were removed out. The machine tool could work again.
(During this High Power SFX-4000B Broken Tap Remover processing, the work liquid replaced tap water due to the cast iron material. )
Super Big bolts Removal Instance on The Wind Power Generation Equipment, Amazing!
Ten Years of Accumulation, Opportunities Knock the Door
Setting: an office, mid-morning
The sales division of Luoyang Xincheng Precision Machinery Co.,Ltd received an extraordinary call at 25th, June, 2015.
Sales person pressed the speakerphone button as usual.
Customer: “Hi, There are several M42×275mm big bolts broken on the Wind Power Generation Equipment , could you help remove them?” (The tone was showing eagerness and anxiousness.)
Sales: Hello, Thanks for your calling, Please tell us in details........ The case is special, after consulting the technical division, we will call back to you.
Here, Let me introduce ourselves and our Broken Tap Remover/ Portable EDM machine first:
Luoyang Xincheng Precision Machinery Co.,Ltd (hereinafter referred to as Luoyang Xincheng) was established in 2014, dedicated to provide the best products and service to customers within 10 years. As a responsible manufacturer, Luoyang Xincheng strives for perfection, tries to make the products unique and superior. Patented portable EDM machine is the ultimate solution to solving broken tools. This machine can fast and easily remove broken taps, reamers, drills, screws by spark erosion, thus no external force and damage to the work piece. Our broken tap remover could also mark and process holes on conductive metals which can't be drilled by conventional methods.
Portable EDM machine occupied more than 70% market share in the domestic market now. And our products has gained a great success both at home and abroad. The exported country includes Asia, Europe, Oceania, America including the Turkey,India,Israel, Korea,Singapore,Australia,Romania,France, Mexico Czech,US etc.. The machine has been awarded seven patents for innovative design. CE
and ISO Certifications attest to the high quality of the products.
Owning to effort and endeavour to perfect products and the spirit of striving for perfection to serve an industry , Luoyang Xincheng has gained the reknowable reputation in the industury, This call Knocks the door to an big appotunity to chanllege Luoyang Xincheng, but not occured by accident, ushers a new chapter of Technical Master Liu and Luoyang Xincheng.
The customer who called us is China Energy Construction Group Co., Ltd at Kunming, Yunnan . The problems is four hex bolt with tightening torque broken in holes on a flange with two meters diameter in the wind power plant. Because of difficulty, they have shelved the problems more than three months, still cannot remove them for now, causing huge losses and waste. In the meantime, the company has ever to tried to find a solutionto the problems, but in vain. Hearing there were professional company aims to remove broken taps/bolts, they were more than pleased to contact Luoyang Xincheng immdiately.
Experimental research, steady progress.
Opportunities always favor those who are prepared, Luoyang Xincheng’s Technical team does not fight the battle without preparation. According to the photos returned on site and bolt sample sent by China Energy Construction Group Co., Ltd, an initial solution was quickly made by Master Liu and other technicals in the team together. Based on the bolt’s model,hardness, fracture etc.. The team first made a simulation experiment.
Operating condition is rough. For the bolts were broken in the holes and had been leaven there for more than 3 months. The hardness of bolt is 10.9, and bolts tightening is made by hydraulic wrench with the 4600N · m torque. Needn't to say, this kind of broken bolt is very difficult to remove out. However, cause of foucus, prfessional, we know that practice makes perfect. Special technical solutions has been designed by Master Liu and team members before this operating. They are specialist at removing broken bolts , threads protection and how to find the processing point of busted bolts .They got rich experience and confidence.
This time, Confronted with the new chanlege, Master Liu prepared a set of mysterious tools to execute this task.
Long-distance Battle, South of Sunny Cloud
17th, July, Master Liu arrived Kunming, Yunan, with the tailor-made tools.Climbed to the 85m tower, reached the nacelle turbines, Master Liu saw the four broken bolts. On the two meters diameter large flange, evenly distributed 60 pieces of M42 × 275mm big bolts by circumference with four of them broken.
In the Cabin, Master Liu took out the mysterious weapon --200W pixel high-definition snake tube probe! Using this probe, he carefully reviewed the fracture situation of the broken bolts, analyzes and removed the first bolt based on his rich experience.
After installing the professional equippment, our High Power Broken Tap Remover-SFX4000B, Master Liu stayed at the cabin all day, despite the hard environment. Confronted with the paralyzed power generation equipment for more than three months. He worried about only one thing--The power plant cost nearly 20 million, quickly fix it will save money for customer and the country. Most people eager to fix it quickly, do best to fight a fight! Moreover, before, the company leaders also told him "do the best work, save money for customers. "Honesty deserves sincere, behavior before work”, earnest words, still ringing in his ears.
Then, Master Liu stayed at the site, forget all about eating and sleeping, indulged in removing the broken taps.
However, the real situation at site is worse than than predicted, when removing the fourth bolt, Master Liu suddenly found the bolt is severely deformed, because the China Energy Construction Group Co., Ltd has drilled by themselves before and they drilled not centered on the core. In this case, the tools Master Liu brought is not enough, How can solve the problem?
Faced with new arising problems, Master Liu spared no efforts to solve it. No suitable tool to aid at site, Master Liu went down the work piece to find. Hard work pays off, Master Liu found a piece of wood, a good idea come across. Use the wood to make a modification of the original tools.
Four stubborn 10.9 hardness large bolts were removed off eventually! And there is no damage to the original thread! All cheers at site when the problems is solved, the power plant can start to work now.
Every time when young Master Liu saw the achievements, proud arises spontaneously, blended with an indescribable feeling in his heart. Now the feeling grasps him again. At the moment, he suddenly understood that this feeling’s name is satisfaction, satisfaction for helping solving the problems for customer.
Hearing the good news, all members of China Energy Construction Group Co., Ltd cheers, the relevant leaders repeatedly appreciated Liu master for solving this big problem in a short time. He saved a significant equipment, avoiding large losses for them. China Energy Construction Group Co., Ltd also edits 3 reports, 3000 words, showing respect for Master Liu and Luoyang Xincheng!
Soon after, the wind power restarts operating. A beautiful picture springs to my mind. On uplift hill, rows huge "windmill" with their beautiful three rotating blades, doing their hard work and selfless dedication at each quiet morning, evening, and night!