Application Technology of the Shenyang Machine Tool IVT45 Inverted Lathe in Flange Disc Machining

Flange plates, as core components for mechanical connections and pipeline sealing, are widely used in industries such as petroleum, chemical engineering, automotive, and construction machinery. Their machining accuracy—such as the flatness of the sealing surface and the positional accuracy of bolt holes—and processing efficiency directly affect the reliability of subsequent assembly and production cycle times. Shenyang Machine Tool IVT45 Thanks to its modular design, high-precision control, and efficient chip evacuation, the inverted lathe has become the preferred machine for machining flanges in small to medium batch sizes, enabling integrated, high-efficiency processing of flanges from roughing to finishing. Below, we will briefly and clearly outline the key application points, supported by real-world machining scenarios. 

I. IVT45 Core Features of the Inverted Lathe (Tailored to Flange Disc Machining Requirements)

Shenyang Machine Tool IVT45 This is a modular, inverted CNC lathe specifically designed for the batch machining of rotational parts. Its core features are perfectly aligned with the machining requirements of flanges and other disc-shaped components, enabling rapid deployment into production without complex setup or adjustment. The key features are as follows: 

1. High-precision assurance

Adopt SKF/FAG Well-known brand bearings, paired with high-quality linear guides and ball screws, deliver high positioning accuracy and stable operation, meeting the requirements for flange sealing surfaces. Ra1.6~Ra6.3μm the roughness requirements, as well as the bolt holes ±0.1 mm Positional tolerance requirements to prevent sealing leaks and loose connections during assembly.

2. Efficient chip evacuation design

‌ Adopts an inverted spindle structure. + The bed features a large-tilt guard design that allows metal chips generated during machining to fall naturally under gravity, preventing accumulation on the flange sealing surfaces or in machined areas. This reduces the risk of chip-induced surface damage to workpieces, lowers manual cleaning costs, and enhances machining continuity.

3. Compact and energy-efficient

The compact machine design occupies a small footprint, optimizing workshop layout and reducing facility costs; it supports standalone automated operation and can be integrated with centralized loading/unloading conveyors and robotic arms to enable single-operator multi-machine management, significantly lowering labor requirements and meeting the demands of high-volume flange production.

4. Flexible adaptation

The maximum machining diameter can reach 450mm , capable of covering the vast majority of small and medium-sized flange specifications; optionally equipped with an electric power turret, it can perform multiple machining operations on flanges, including turning, drilling, boring, and tapping, eliminating the need to change equipment and achieving “ One clamping, full-process machining ” , to avoid precision errors caused by multiple setups.

II. IVT45 Inverted Lathe Flange Disc Machining Process

‌ With the common 45# Steel flange (outer diameter ≤450mm , taking the type with a sealing surface and evenly distributed bolt holes as an example, relying on IVT45 Due to the characteristics of the inverted lathe, the machining process is simplified to: 5 A core set of steps—no complicated process integration required, so even beginners can get up to speed quickly: 

Steps 1 : Blank Preparation and Clamping 

Selected from forgings or plate cuttings 45# The steel blank is first subjected to annealing to relieve internal stresses and improve machinability; the blank is then processed through IVT45 Hydraulic chuck clamping, using the blank’s outer diameter as the rough datum and leveraging the machine tool’s precise positioning capabilities to ensure clamping accuracy. ≤0.02 mm , thereby preventing eccentricity during subsequent machining. No additional fixture adjustments are required during clamping; the circular design of the flange adapter ensures higher clamping efficiency compared with conventional lathes. 30% That's all. 

Steps 2 : Rough machining (removing stock and forming the basic shape) 

Start IVT45 The CNC system calls the pre-set roughing program for the flange, using an end-turning tool and an external turning tool to sequentially perform rough turning of the flange’s end face, outer diameter, and center hole, thereby removing most of the machining allowance (leaving 0.2~0.3mm Finishing allowance). The spindle speed of the equipment can be adjusted flexibly ( 0~3000 r/min ), the cutting speed is automatically optimized based on the stock allowance, thereby preventing tool chipping and workpiece deformation, and increasing rough-machining efficiency compared with conventional lathes. 25%。

Steps 3 : Finish machining (ensuring accuracy and meeting requirements) 

After rough machining is completed, there is no need to remove the workpiece; the system automatically switches to the finish-machining program, which focuses on the core areas of the flange: a finishing turning tool is used to precisely machine the sealing surface and end face, ensuring flatness and surface roughness; an internal-bore boring tool is employed to precisely bore the center hole, guaranteeing cylindrical accuracy of the center hole and perpendicularity to the end face; if the flange features stepped geometry, the step surfaces are also finished in a single operation. The entire process is fully automated, with dimensional tolerances maintained within ±0.01 mm Within this range, the flange assembly requirements are fully met. 

Steps 4 : Auxiliary machining (bolt hole machining, completed in one step) 

For flanges with bolt holes, utilize IVT45 An optional power turret is available, enabling drilling, reaming, boring (or tapping) operations to be performed directly on the machine tool, eliminating the need to transfer the workpiece to a separate drilling machine and thereby preventing positional deviations in bolt holes caused by multiple setups. The equipment allows programmatic setting of the evenly spaced angular distribution and hole diameter for bolt holes, accommodating the machining requirements of flanges with different specifications; hole-position accuracy can reach ±0.1 mm , to meet the bolt alignment requirements during assembly. 

Steps 5 : Self-inspection and material cutting 

After machining is completed, use the machine’s built-in measurement functions (or external measuring tools) to inspect the flange’s critical dimensions—outer diameter, sealing-face flatness, and bolt-hole positional accuracy. Once verification confirms compliance with the drawing requirements, activate the automatic part-discharge function to complete processing of a single flange. The entire machining process requires no manual intervention, and the cycle time per part is significantly shorter than with conventional machining methods. 40% The above is suitable for medium- to large-scale production needs.

Three 、IVT45 Inverted Lathe Flange Disc Machining Process

1. Core Processing Advantages

• High efficiency and energy savings: Multiple machining operations can be completed in a single clamping, reducing setup time and workpiece handling, thereby significantly boosting productivity; one operator can manage multiple machines, lowering labor costs; the compact design saves shop-floor space, indirectly reducing production costs. 
• Stable precision: The equipment boasts high inherent positioning accuracy, and its inverted structure minimizes chip interference, thereby eliminating precision errors caused by multiple setups. As a result, the yield of qualified flange blanks can reach 99.5% Above all, reduce waste and scrap. 
• Simple operation: The CNC system features a user-friendly interface and allows pre-setting machining programs for flanges of various specifications. Subsequent operations require only calling up the program and clamping the workpiece, eliminating the need for complex programming and debugging and thereby lowering the skill requirements for operators. 
• Wide adaptability: capable of machining flanges made from various materials, including carbon steel and stainless steel, with a maximum machining diameter of 450mm , covering mainstream specifications for small and medium-sized flanges to meet the machining needs of various industries. 

2. Simple Precautions

• During workpiece clamping, the surface of the blank must be cleaned to remove oil, dirt, and other contaminants, ensuring secure clamping to prevent workpiece loosening during machining and thereby maintaining machining accuracy. 
• Prior to machining, inspect the cutting tools for wear and replace them promptly to prevent tool wear from causing scratches on the sealing surfaces and dimensional deviations in hole diameters. 
• Regularly clean the chip evacuation channels of the equipment to ensure smooth chip removal and prevent chip accumulation from compromising machining continuity and workpiece quality. 
• When machining flanges made of different materials, the cutting speed and feed rate must be adjusted (for example, the cutting speed should be reduced for stainless steel flanges to prevent built-up edge), and the machine’s built-in parameter recommendation table can be consulted. 

Four 、 Application Summary

Shenyang Machine Tool IVT45 Thanks to its high precision, high efficiency, and user-friendly operation, the inverted lathe is perfectly suited to the medium-volume machining of flanges, thereby resolving the issues inherent in traditional machining processes. “ Insufficient precision, cumbersome processes, and low efficiency ” addressing key pain points. Its inverted spindle and power turret designs enable the integrated completion of flange machining—from roughing to finishing—thereby ensuring high machining accuracy while significantly reducing labor and facility costs. This solution is well-suited for flange machining applications across multiple industries, including automotive, petroleum, and construction machinery. 

For small- and medium-sized flange manufacturing enterprises, IVT45 The inverted lathe can be quickly put into production without the need for complex auxiliary equipment, effectively boosting production efficiency and product quality rates, making it a cost-effective choice for flange machining.