Stainless steel forging pipe plate deep hole processing

In 2010, our company was tasked with manufacturing a reflux condenser for the 400,000-ton urea plant of Shandong Runyin Biochemical Co., Ltd. The key component of this equipment was the tube sheet, which had an outer diameter of 1,960 mm and a thickness of 150 mm, made from 00Cr17Ni14Mo2 stainless steel. According to the engineering drawings, the tube sheets were required to be manufactured and accepted in accordance with Class II forgings specified in JB4728-2000 "Stainless Steel Forgings for Pressure Vessels." The unit consisted of two tube sheets and nine baffles, with each baffle measuring φ1,790 mm × 20 mm. Each tube sheet contained 2,576 tube holes, arranged in an equilateral triangular pattern as shown in Figure 2. The design specifications were particularly challenging. After drilling, 96% of the hole bridge width needed to be at least 5.77 mm, with a minimum allowable width of 3.48 mm. Additionally, the tube holes had to be strictly perpendicular to the sealing surface, with a perpendicularity tolerance of 0.08 mm. Given the length-to-diameter ratio of 6, these were classified as deep holes, making the process extremely difficult. At that time, we did not have CNC or deep-hole drilling machines, so we relied on the existing Z3080 radial drilling machine for the task. This posed significant risks, as the accuracy of tube spacing, diameter tolerance, verticality, and surface roughness directly affected the performance and assembly of the heat exchanger. Any small deviation could lead to serious issues, such as oversized holes. To ensure high-quality drilling under these constraints, we conducted a detailed analysis of the challenges and developed a comprehensive processing plan. The main difficulties included: 1. A large number of tube holes with strict tolerances on the hole bridge width. 2. High precision requirements for the verticality of the holes, especially given the thick tube sheet. 3. Strict concentricity between the tube sheet and the baffles, which is critical for proper tube insertion. 4. The material, 00Cr17Ni14Mo2, has high plasticity and work hardening properties, leading to increased tool wear and difficulty in chip removal. 5. The chips produced during drilling are long and tend to wrap around the drill bit, causing damage to the inner walls of the holes. To address these challenges, we implemented the following steps: **Scribing:** To ensure accurate positioning, we used a scribe line on the baffle plate and then drilled locating holes. We adopted a method of scribing from the outside inward, starting with finding the center and drawing crosshairs. By using a regular hexagon layout, we minimized cumulative errors and achieved a position error within 0.2 mm. **Drilling:** We first drilled a φ6mm positioning hole, followed by a φ23mm twist drill. The tube sheet was placed on a flat workbench to maintain verticality. Drilling was done in multiple passes to improve chip evacuation and cooling. **Reaming:** After initial drilling, we reamed the holes using a φ25.4mm reamer to achieve better surface finish and dimensional accuracy. **Cutting Fluid:** We used a 10% emulsion as the cutting fluid to manage heat dissipation and prolong the life of the drill bits. **Cutting Parameters:** We set the drilling speed at 105 r/min with a feed rate of 0.32–0.4 mm/r, and reaming at 200 r/min with a feed rate of 0.45–0.6 mm/r, which improved both efficiency and quality. Through careful planning and execution, we successfully completed the drilling process, meeting all technical requirements. Key lessons learned include ensuring the shortest possible drill bit length for rigidity, maintaining sharp tools, and monitoring chip flow to avoid blockages. This project demonstrated the importance of adaptability and precision in overcoming complex machining challenges.

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