TDP-52 Long-Stroke Horizontal Foam Boring Machine 2300 mm for Cylinder Peeling Lines

 Horizontal Long-Stroke Foam Boring Machine 2300 mm Boring Length 45-80 mm Boring Diameter for Cylinder Peeling Lines

The TDP-52 is a horizontal boring machine that drills a centered hole through cylindrical PU foam before the block moves to a peeling machine. It uses a 230 r/min spindle, a 1.5 kW motor and a drill range of 45–80 mm, with a maximum boring length of 2300 mm. The frame measures 6000×1500×1800 mm and weighs 800 kg, keeping the station compact enough to fit between a foaming line and a peeler without rebuilding the plant layout.

This page focuses on the part of the job that is easy to underestimate: keeping a 2300 mm bore straight. A horizontal drill with a long overhang behaves differently from a short drilling station. The drill can wander, chips can pack in the flutes, and a block that is not supported at the right height will produce a hole that is straight at the entry and off center at the exit. The sections below cover drill guidance, feed, chip clearance, block support, bore measurement, changeover and line alignment, in the order a production engineer would set the machine up.

• Model: TDP-52
• Boring diameter: 45–80 mm
• Boring length: max 2300 mm
• Main shaft speed: 230 r/min
• Positioning accuracy: ±0.05 mm
• Motor power: 1.5 kW
• Machine weight: 800 kg
• Overall dimension: 6000×1500×1800 mm
• Certification: CE

• Straight bore over a long stroke: the drill is guided along the frame instead of being overhung from a short carriage, which limits the wander that shows up at the far end of a 2300 mm block.
• Compact footprint for the bore length: a 6000×1500×1800 mm frame and 800 kg weight fit into an existing cylinder line without a new foundation design.
• Low connected load: a 1.5 kW motor drives the spindle; the station does not add a large electrical load to a line that already runs a foaming machine and a peeler.
• One drill range for several products: 45–80 mm covers foam tubes, rollers and cushion cores, so one machine serves more than a single order size.
• Simple mechanical setup: the working settings are mechanical and repeatable, which suits a plant that changes block size a few times a week rather than every hour.
• Matched to the peeling line: the discharge height and spindle axis can be aligned with the peeler infeed, so the block transfers without a second lift.

On a short drilling station, the drill is stiff relative to its overhang and the bore follows the spindle. On a 2300 mm stroke, the drill is long, the overhang grows as the carriage advances, and three things start to matter:

1. Guidance: the drill must be supported close to the cutting edge or guided along the stroke. A long unsupported drill deflects under cutting force and follows the softer path in the foam.
2. Chip clearance: foam chips have nowhere to go in a deep hole. If the flutes pack, friction rises, the drill heats and starts to wander. Peck feeding and retraction give the chips a path out.
3. Block support: the block must be supported along its length at the same height as the spindle axis. A block that sags at the far end presents a hole that is centered at the entry and low at the exit.

These three points are the practical difference between a machine that drills a 500 mm hole well and one that holds a 2300 mm bore. The TDP-52 addresses them with a guided carriage, a horizontal frame that carries the full stroke, and a loading side that lets the operator set the block support before clamping.

1. 1Load the block. Place the cylinder on the support with the end facing the drill. Confirm that the block is clear of the frame and that the support height matches the spindle axis.
2. 2Align the center. Bring the block center to the spindle axis. The machine positioning accuracy is ±0.05 mm; the practical result still depends on the block being seated and supported correctly.
3. 3Clamp. Hold the block so it cannot rotate or slide under drilling thrust. On foam, clamp pressure should be enough to hold, not enough to compress the section.
4. 4Start the spindle. Run the spindle at 230 r/min and bring the drill to the entry face.
5. 5Feed and clear chips. Advance the drill, retracting periodically to clear chips from the flutes. Watch the entry for tearing and listen for a change in sound.
6. 6Complete the stroke. Continue to the required depth. For a through bore, watch the exit face so the drill does not tear the last layer of foam.
7. 7Retract and unload. Withdraw the drill, release the clamp and move the block to the peeling machine or the next station.

The drill is the only part that touches the bore wall, so its condition and guidance decide the surface quality. A sharp drill with open flutes cuts; a dull or packed drill rubs, heats and wanders. For the 45–80 mm range, match the drill to the bore and to the foam grade, and inspect it at the start of each shift rather than waiting for a rejected block.

• Sharpness: a dull edge tears the entry and exit, and torn foam cannot be repaired downstream.
• Flute clearance: chips must leave the hole. Packed flutes increase friction and heat, and the drill starts to follow the soft side.
• Mounting: a drill that is not seated squarely runs off axis even when the block is centered.
• Feed: too fast a feed compresses the foam ahead of the edge; too slow a feed rubs and generates heat.

On denser foam and on long bores, peck feeding is the practical control. Advance a short distance, retract to clear the flutes, then advance again. The extra stroke time is small compared with the cost of a bore that has to be scrapped.

Foam chips are light, but they do not flow out of a deep horizontal hole on their own. They compact against the drill land, and once the flutes are full the drill behaves like a friction tool. The symptoms are easy to recognise: the sound changes, the feed resistance rises, the bore wall looks glazed, and the drill starts to drift.

Three habits keep the bore clean:

• Peck feed: retract at intervals so the flutes can discharge. The interval depends on the foam and the bore depth; short intervals at the start of a deep bore are less costly than a stalled drill.
• Clear the machine between blocks: chips that fall on the support change the block height, and a block sitting on a chip is bored off center.
• Check the drill after a jam: a drill that has been stalled in foam may have a damaged edge. Inspect it before the next block rather than after the next rejection.

Clamping holds the block; support sets its height. Both matter on a long block. If the support is low at the far end, the block tilts and the bore rises or falls along the length. If the clamp is too tight, the foam compresses and the bore closes slightly behind the drill.

Set the support height against the spindle axis before loading the first block of a batch, and check it again after a change of block diameter. On a 1200–1500 mm block, a few millimetres of support error is enough to move the exit bore off center. The check takes a minute and saves the block.

A bore that looks centered at the entry can still be off at the exit. The acceptance check has to look at both ends and at the wall between them.

1. Entry and exit position: measure the bore center relative to the outside diameter at both ends. The difference is the practical straightness error.
2. Wall thickness: measure at four points around the bore at the entry, middle and exit. A thin wall on one side shows eccentricity or tilt.
3. Bore diameter: check with a gauge or the mandrel that will be used downstream. An oversize bore lets the block shift on the bar.
4. Surface: look for torn foam, glazing or a spiral mark. Each points to a different cause: dull drill, packed flutes or feed that is too fast.

Record the result for the first block of each batch and after every changeover. If the exit position drifts, check support height and drill condition before changing the feed.

Boring diameter, maximum boring length and spindle speed define what the standard TDP-52 accepts. Blocks longer than 2300 mm, or bores outside 45–80 mm, need a different configuration and should be checked before ordering.

Changing bore size is a setup task with four checkpoints:

1. Drill: fit the drill for the new bore and confirm it is seated squarely.
2. Guide: match the guide or bushing to the drill so the long stroke stays supported.
3. Support height: re-check the block support against the spindle axis for the new block size.
4. Trial bore: drill one block and measure entry, exit and wall thickness before releasing the batch.

Keep the changeover parts in a marked set. A missing guide is usually replaced with whatever is on the shelf, and that is how a good machine starts producing off-center bores.

1. Vertical cylinder foaming: produces the round block.
2. Curing: the block rests until it can be handled and bored.
3. TDP-52 boring: the center hole is drilled on the horizontal spindle.
4. Peeling or skiving: the block rotates on the bar against the blade.
5. Winding or cutting: the peeled sheet moves to the next process.

The practical layout question is the transfer height. If the TDP-52 discharge and the peeler infeed are at the same height, the block moves with one transfer. If they are not, the block has to be lifted and re-centered, and the centering work done at the drill is partly lost. Set the height during layout, not on the first production day.

Boring is a single-station operation, so output is set by cycle time. The cycle is loading, alignment, clamping, drilling, retraction and unloading. Blocks per hour is 3600 divided by that cycle in seconds.

On a long bore, the drilling portion is usually not the bottleneck; the handling and the chip-clearing retracts are. Two levers matter:

• Block handling: a roller conveyor or transfer table shortens loading and unloading more than a higher feed rate shortens drilling.
• Buffer: keep one block ahead of the drill and one behind it so the station is neither starved by curing nor blocked by the peeler.

Plan capacity around the peeler, which is normally the constraint. The TDP-52 only needs to keep it fed; pushing the drill harder adds wear without adding saleable sheet.

• Bore size: confirm the mandrel or tube diameter sits inside 45–80 mm.
• Block length: confirm the block fits within the 2300 mm maximum bore length.
• Block diameter and support: confirm the support can hold the cylinder at the spindle height for the full length.
• Space: the frame is 6000×1500×1800 mm; leave access at both ends for loading and unloading.
• Power: a dedicated supply for the 1.5 kW motor with correct earthing and a local isolator.

An 800 kg machine still needs a level, load-bearing floor. Leveling matters more than the weight suggests, because the frame carries the full stroke and any twist shows up as a bore that changes height along the block.

The TDP-52 is used where a cylindrical foam block needs a center hole before peeling, or where a finished foam tube needs a clean bore.

• Foam tubes and sleeves: center holes for cushion tubes, roller covers and protective sleeves.
• Rebonded foam tubes: bores for packaging, sound insulation and buffer products.
• Cleaning and textile rollers: foam rollers with a straight center bore for shaft mounting.
• Furniture rollers and bolsters: cylindrical foam parts for upholstery and seating.
• Cushion cores: center bores for cushion assemblies and support pads.
• Pipe insulation: foam sleeves bored to fit over pipe or liner.
• Shock absorption parts: cylindrical foam components with a centered mounting hole.

Installation starts with the floor and the frame. Level the frame, check for twist, anchor it, then align the spindle axis with the block support. After mechanical alignment, run an empty stroke to confirm the carriage travel and the drill path before loading foam.

Commissioning then moves to a trial block: set the support, clamp, drill a full-length bore and measure entry, exit and wall thickness. That trial sets the baseline for the batch. Operator training covers block seating, support height, feed and chip clearing, and the halt procedure for a jammed drill.

The station has a rotating drill, a moving carriage and a clamped foam block. Guards cover the drill and carriage path, and the halt circuit must be reachable from the operator position.

• Do not reach into the drill or carriage area while the spindle is energised.
• Confirm the block is seated and clamped before starting the feed.
• Halt the cycle if the drill sound changes or the carriage resistance rises.
• Lock out the machine before clearing a jam or changing the drill.
• Keep the floor clear of foam chips and offcuts.
• Wear eye protection when clearing chips from the bore area.

Operator training should focus on three habits: seated block, correct support height, and an immediate halt when the sound changes. These prevent the majority of bore defects and jammed drills.