Challenges in Wind Power Industry Machining

·Wind turbine main shaft: Large size, high-hardness materials, high surface precision requirements.

·Hub: Interrupted cutting, complex structure, material hardness.

·Gear: High-hardness materials, high precision requirements, tool life.

·Bearing: High wear resistance requirements, high material toughness, machining efficiency.

Comprehensive Solution Introduction

Halnn can provide a series of solutions for wind power bearings such as gear milling tools, crown drills, bearings raceway hard turning CBN tools, outer circle rough turning tools

Recommended inserts: solid CBN inserts, CBN full face inserts

Processing type: continuous, light-interrupt, semi-interrupt

Workpiece material: hardened steel, bearings steel, 42CrMo4

Workpiece hardness: above HRC45

Insert grade: BN-H200

Recommended Tools for Different Machining Processes

Pre-heat turning (Carbide Inserts)

  ·Suitable for gear end faces and inner holes before heat treatment, outer rings and grooves of bearing raceways, as well as rough machining of planetary gears, sun gears, and Transmission Shafts.

  ·Features deep cutting and high efficiency.

Post-heat hard turning (CBN Inserts)

  ·Suitable for outer diameters, end faces, and inner holes of gears with a hardness of HRC60 after heat treatment.

  ·Provides wear resistance and stability, ensuring excellent surface roughness.

Rough Milling Cutter

  ·Suitable for modules 6-30, profile accuracy ±0.1mm.

  ·Cutter diameter 200-500mm, maximum cutting depth 50mm.

  ·Optimized design ensures even distribution of cutting forces, improving machining performance.

Pre-Grinding Milling Cutter

  ·Suitable for 8-9 grade gear machining, cutting speed 130-200m/min.

  ·High tooth profile accuracy reduces subsequent grinding costs and improves machining efficiency.

High-Speed Pre-Grinding Hob

  ·Suitable for rough and semi-finish machining of M5-M38 gears.

  ·Available in different tooth layouts, such as integral and modular designs.

  ·Provides higher cutting speeds, ensuring stable production efficiency.

Shaping Cutter

  ·Suitable for machining M3.5-M10 small module gears.

  ·Indexable inserts eliminate the need for regrinding, improving production efficiency.

  ·Ideal for machining internal gears of small workpieces, with V-shaped positioning ensuring reliable insert fixation.

Crown Drill

  ·Polished flute design for optimized chip evacuation.

  ·Cylindrical fit structure ensures tool concentricity, improving machining stability.

  ·Internal coolant design effectively enhances cooling and extends tool life.

Interrupted Thread Milling Cutter

·Suitable for M30-M64 threading, with pitches of 0.5-10mm.

·Indexable tool design reduces costs for large-diameter threading.

·Internal cooling system effectively improves chip evacuation and cooling.

Thread Taps

·Suitable for processing materials with hardness HB280-330.

·Offers excellent chip handling and stable guidance performance.

Milling Tools

  ·Multi-edge double-sided insert design improves material removal rates.

  ·High feed machining enhances production efficiency.

Crown Drill (Hole Machining)

  ·Quick-change head design eliminates the need to remove the tool body from the machine.

  ·Internal coolant design optimizes cooling and extends tool life.

Three-Edge Milling Cutter

  ·Suitable for diameters ranging from D100-D400.

  ·Low-resistance insert design reduces vibration and improves stability.

Vibration-Damping Face Milling Holder

  ·Suitable for long overhang and deep cutting applications.

  ·Damping structure extends tool overhang range and improves machining capability.

Processing Case

1.2750 Inner ring processing case

Difficulties: the wear resistance of the blade is poor, the size of the pressure angle machined to the lower channel is out of tolerance, the roughness is out of tolerance, and the workpiece surface has scratches. 

The BN-H200 material has excellent wear resistance and can easily solve customers' problems

Parts：Rough finishing of inner ring ribs Diameter：2750mm Material：42CrMo4 Hardness：HRC58-63 Type：BN-H200 RNMN090300 Machining parameter：Vc=190m/min, Fr=0.32mm/r, ap=0.6-0.7mm

2. 2750 outer ring processing case

Difficulties: 1-1.5mm Cutting depth;

                     Heavy interrupted cutting;

                     Insufficient wear resistance.

BN-H200 High wear resistance and strong impact resistance

If you have any questions, please contact our Executive Manager and we will get back to you as soon as possible