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Custom PEEK Tubing, High-Performance Wind Turbine Bushings & Insulators
Header include
This product is a large customized core structural component made from high-performance special engineering plastic pipes based on polyetheretherketone (PEEK) through precision mechanical processing. Its design strictly adheres to the harsh working conditions of the new energy wind power industry, aiming to replace traditional metal components to achieve the operational goals of lightweight, corrosion resistance and long-term stability. The main body of the product is a super-large-sized PEEK tube blank (80mm/ 60mm×4500mm), and through precise processing of outer circular steps at both ends, it meets the specific installation and functional requirements in wind power equipment.
Abject of manufacture
1.Base material: PEEK (polyetheretherketone). This material is hailed as the "King of Plastics", featuring outstanding mechanical strength, fatigue resistance, self-lubrication, excellent chemical corrosion resistance and inherent flame retardancy. It is an ideal choice for dealing with the vibration of wind power equipment, grease media and harsh environments.
2.Blank form: Extruded PEEK thick-walled tubes, with specifications of outer diameter 80mm × inner diameter 60mm × length 4500mm.
3.Final form: At both ends of the original pipe material, a precision outer circular step of 70mm × 350mm is processed, forming a unique "step shaft" structure, which is used for bearing positioning, sealing assembly or connection with adjacent components.
Core features and requirements
1.Advantages of high-performance materials: The use of PEEK material directly results in a lighter weight than metals, inherent electrical insulation, low noise during operation, and excellent resistance to salt spray and moisture, significantly enhancing the reliability and lifespan of wind power equipment in harsh environments.
2.Super-large size and structure: With a total length of 4500mm and an outer diameter of 80mm, it falls within the category of large plastic parts processing, which poses extremely high requirements for the stroke, rigidity of the processing equipment, as well as the support and anti-deformation of the workpiece during the process.
3.Strict tolerance control: Although it is a large plastic part, the total length tolerance is strictly controlled within ±0.1mm. This ensures that the component can be precisely installed in the entire transmission or support system, avoiding assembly stress or functional failure caused by cumulative dimensional errors.
4.The features of the precise steps: The 70mm outer circular steps at both ends need to maintain good coaxiality with the pipe body. Their diameter size, length (350mm) and surface finish directly affect the connection quality and sealing effect with the mating parts.
Key processes and technologies
To ensure compliance with the above requirements, the manufacturing process needs to overcome the challenges brought by the properties of PEEK material and the processing of large parts:
1.Customized support and clamping solutions for long tube billets：
This is the primary prerequisite for achieving successful processing. It is necessary to design a dedicated following center rest or multi-point support bracket to provide stable support for the tube blank throughout the 4.5-meter-long machine tool, effectively suppressing the vibration and deformation caused by gravity sagging and cutting force.
2. Precision machining on CNC lathes:
(1)Role: Core equipment for processing the steps at both ends, preferably large horizontal lathes or CNC boring machines.
(2)Technology
Segmented processing: First, precisely process one end of the step to ensure a size of 70mm and a length of 350mm. Then, without turning around or using a precise turning process, process the other end with the already processed end as the reference to ensure the coaxiality of both ends.
Tools and parameters: Select sharp hard alloy tools, adopt a cutting strategy of small depth of cut, fast feed, and high speed, and supplement it with sufficient cooling (such as compressed air or special cutting fluid) to prevent PEEK material from softening due to overheating or generating internal stress
Online measurement: During the processing, it is necessary to frequently use external micrometers, calipers and laser rangefinders, etc. for online dimensional detection, and dynamically adjust the tool compensation to ensure the tolerance requirements of ±0.1mm for the total length and the step diameter
3.Quality control and post-processing:
(1)After processing is completed, a large platform and a three-coordinate measuring machine need to be used to conduct the final inspection of the total length, step dimensions and positional tolerances.
(2)Precisely chamfer or deburr all sharp edges to prevent the seal from being scratched during installation.
Conclusion
This PEEK part is a perfect blend of high-performance materials and precision manufacturing technology. It has successfully transformed the outstanding properties of PEEK, such as its lightweight, fatigue resistance and corrosion resistance, into a core solution that meets the demanding requirements of the wind power industry through customized precision processing, featuring high reliability and long service life. This demonstrates its advanced capability to achieve high-precision manufacturing in large engineering plastic parts.
Custom PEEK Tubing, High-Performance Wind Turbine Bushings & Insulators
Header include
This product is a large customized core structural component made from high-performance special engineering plastic pipes based on polyetheretherketone (PEEK) through precision mechanical processing. Its design strictly adheres to the harsh working conditions of the new energy wind power industry, aiming to replace traditional metal components to achieve the operational goals of lightweight, corrosion resistance and long-term stability. The main body of the product is a super-large-sized PEEK tube blank (80mm/ 60mm×4500mm), and through precise processing of outer circular steps at both ends, it meets the specific installation and functional requirements in wind power equipment.
Abject of manufacture
1.Base material: PEEK (polyetheretherketone). This material is hailed as the "King of Plastics", featuring outstanding mechanical strength, fatigue resistance, self-lubrication, excellent chemical corrosion resistance and inherent flame retardancy. It is an ideal choice for dealing with the vibration of wind power equipment, grease media and harsh environments.
2.Blank form: Extruded PEEK thick-walled tubes, with specifications of outer diameter 80mm × inner diameter 60mm × length 4500mm.
3.Final form: At both ends of the original pipe material, a precision outer circular step of 70mm × 350mm is processed, forming a unique "step shaft" structure, which is used for bearing positioning, sealing assembly or connection with adjacent components.
Core features and requirements
1.Advantages of high-performance materials: The use of PEEK material directly results in a lighter weight than metals, inherent electrical insulation, low noise during operation, and excellent resistance to salt spray and moisture, significantly enhancing the reliability and lifespan of wind power equipment in harsh environments.
2.Super-large size and structure: With a total length of 4500mm and an outer diameter of 80mm, it falls within the category of large plastic parts processing, which poses extremely high requirements for the stroke, rigidity of the processing equipment, as well as the support and anti-deformation of the workpiece during the process.
3.Strict tolerance control: Although it is a large plastic part, the total length tolerance is strictly controlled within ±0.1mm. This ensures that the component can be precisely installed in the entire transmission or support system, avoiding assembly stress or functional failure caused by cumulative dimensional errors.
4.The features of the precise steps: The 70mm outer circular steps at both ends need to maintain good coaxiality with the pipe body. Their diameter size, length (350mm) and surface finish directly affect the connection quality and sealing effect with the mating parts.
Key processes and technologies
To ensure compliance with the above requirements, the manufacturing process needs to overcome the challenges brought by the properties of PEEK material and the processing of large parts:
1.Customized support and clamping solutions for long tube billets：
This is the primary prerequisite for achieving successful processing. It is necessary to design a dedicated following center rest or multi-point support bracket to provide stable support for the tube blank throughout the 4.5-meter-long machine tool, effectively suppressing the vibration and deformation caused by gravity sagging and cutting force.
2. Precision machining on CNC lathes:
(1)Role: Core equipment for processing the steps at both ends, preferably large horizontal lathes or CNC boring machines.
(2)Technology
Segmented processing: First, precisely process one end of the step to ensure a size of 70mm and a length of 350mm. Then, without turning around or using a precise turning process, process the other end with the already processed end as the reference to ensure the coaxiality of both ends.
Tools and parameters: Select sharp hard alloy tools, adopt a cutting strategy of small depth of cut, fast feed, and high speed, and supplement it with sufficient cooling (such as compressed air or special cutting fluid) to prevent PEEK material from softening due to overheating or generating internal stress
Online measurement: During the processing, it is necessary to frequently use external micrometers, calipers and laser rangefinders, etc. for online dimensional detection, and dynamically adjust the tool compensation to ensure the tolerance requirements of ±0.1mm for the total length and the step diameter
3.Quality control and post-processing:
(1)After processing is completed, a large platform and a three-coordinate measuring machine need to be used to conduct the final inspection of the total length, step dimensions and positional tolerances.
(2)Precisely chamfer or deburr all sharp edges to prevent the seal from being scratched during installation.
Conclusion
This PEEK part is a perfect blend of high-performance materials and precision manufacturing technology. It has successfully transformed the outstanding properties of PEEK, such as its lightweight, fatigue resistance and corrosion resistance, into a core solution that meets the demanding requirements of the wind power industry through customized precision processing, featuring high reliability and long service life. This demonstrates its advanced capability to achieve high-precision manufacturing in large engineering plastic parts.
