Continued queuing delays between the lathe and the drill led Koso KentIntrol to purchase a multitasking machine from Starrag that could do both.#case analysis
UK-based Koso KentIntrol’s investment in Starrag’s Heckert 630 DBF horizontal machining center has paid off in valve body machining, not least because the machine’s single-group milling, turning and drilling capability eliminates the need for two separate machines. demand – and all associated reset and queue times – to produce finished workpieces.
“In addition to replacing individual machining operations, the Hecht DBF effectively simplifies the production process, allowing us to load raw material in one go, do the full machining, and then unload the finished part for inspection. We get more parts on this machine than we would with a separate machine,” said Richard Addy, machine shop manager.
Founded in 1967, Koso KentIntrol, formerly known as Introl, is a global supplier of a wide range of throttle, control and butterfly valves as well as actuators and instrumentation for the oil and gas, petrochemical and power generation industries.The company purchased Heckert DBF specifically to increase the processing capacity of valves and balls with flanged outlet hole sizes ranging from 1 to 6 inches.These valve bodies are made from a variety of materials, from carbon steel to super duplex stainless steel and Inconel.
The Starrag Heckert 630 DBF Spindle Head includes a faceplate with an integrated work spindle and CNC radial slides.Here, the head is positioned to open the flange.
Previously, the bodies had been operated on on two machines.First, a lathe produces flanges and plug grooves in three steps.Then, the part moves to the drill for final operations.Before, it often had long queues until the drill was idle.Recognizing the need to increase capacity and leverage its existing relationship with Starrag, Koso KentIntrol chose a Heckert 630 DBF using a 630 x 630 mm pallet.The machine has X, Y and Z travels of 1,070, 870 and 1,200 mm, respectively, and rapid traverse speeds of 40, 40 and 60 m/min, respectively.The machine also has a ±35mm U-axis for turning and a 45kW (1,700Nm) spindle.
With DBF, the strategy for corner bodies is done in one setup.For spheres, it requires two setups: one for machining and drilling plug holes, and one for flanges.
The Heckert 630 DBF was not the company’s first Starrag machine.The old Scharmann Ecoforce HT2 with an integrated P600 face head was also used as a single-setup machine for large workpieces at another of the company’s heavy-duty-focused facilities, Mr. Addy said.
“We’ve proven the reliability of Starrag machines and consistently high-quality machining results. Coupled with the excellent aftermarket support and support we’ve always had from the company, when we need to meet the throughput demands of smaller valve bodies, It makes perfect sense to continue this single-source link,” Mr Addy said.
Heckert DBF machines feature an integrated U-axis with Starrag’s DBF multitasking head for a range of internal and external machining operations.The spindle head includes a faceplate with an integrated work spindle and CNC radial slides.For turning of fixed workpieces, rotary turning tools (with an axial runout of approximately 5 to 6 microns) can be radially adjusted by ±70 mm.In addition to external, internal and face turning, the tool head also allows taper and contour turning thanks to the NC axis of the radial face slide.For milling and drilling, the work spindle is arranged in its center.
Mr Addy says the shop makes full use of the machine’s 3,500 rpm spindle, typically using high-feed Capto cutters on carbon steel (WCB) at 850 rpm and 3,000 mm/min feed.He continued: “The machine is very robust, on softer materials we cut 2 to 3 mm deep. For example, on a double-sided body we do a 3 mm cut at 60 m/min and feed speed. Cut. and 0.25mm/rev. But this is a careful balance between depth and speed of cut and tool wear; the goal is to maximize tool life. This is especially true when milling the back of flanges, an operation that The wear on the saw can be particularly heavy.”
One of the most common tapping methods currently used on CNC machines is “rigid tapping” or “simultaneous feed tapping”.Rigid tapping cycles synchronize machine spindle rotation and feed to match a specific thread pitch.Since the feed holes are synchronized, it is theoretically possible to use a solid clamp without any tension-compression.
Post time: Jan-11-2022
