There was always a queue delay between the lathe and the drilling machine, which caused Koso KentIntrol to purchase a multi-purpose machine from Starrag, which was able to do so at the same time. #case study
Koso KentIntrol’s investment in Starrag’s Heckert 630 DBF horizontal machining center has paid off in the machining of the valve body, especially because the machine’s single-cut milling, turning and drilling capabilities eliminate the need for two separate machines -And all related reset and queuing times-to produce finished parts.
“In addition to replacing a separate processing operation, Heckert DBF also allows us to load raw materials at once, perform complete processing, and then unload the finished parts for inspection, which effectively simplifies the production process. This also means that the use of separate machines In comparison, we actually get more parts from this machine every week.”
Founded in 1967, Koso KentIntrol, formerly known as Introl, is a global supplier of throttle valves, control valves and butterfly valves, as well as actuators and instruments used in the oil and gas, petrochemical and power generation industries. The company specially purchased Heckert DBF to improve the processing capacity of valves and globe valve bodies with flange outlet holes ranging from 1 to 6 inches. These bodies are made of a variety of materials, from carbon steel to super duplex steel and Inconel.
The Starrag Heckert 630 DBF spindle head includes a panel with integrated work spindle and CNC radial sliding slide. Here, the head is positioned to open this flange.
Previously, these car bodies were operated on two machines. First, a lathe produced flanges and plug channels through three processes. Then, the part moves to the drill bit for final operation. Before that, it usually stays in the queue until the drill is released. Considering the need to increase production capacity and take advantage of the existing relationship with Starrag, Koso KentIntrol chose Heckert 630 DBF with 630 x 630 mm pallets. The machine’s X-axis, Y-axis and Z-axis strokes are 1,070, 870, and 1200 mm, respectively, and the rapid movement speeds are 40, 40, and 60 m/min. The machine also has a ±35 mm U-axis for rotation and a 45 kW (1,700 Nm) spindle.
With DBF, the strategy for angle steel is to complete machining in one setting. For spherical bodies, two settings are required: one for machining and drilling plug holes, and the other for flanges.
The Heckert 630 DBF is not the company’s first Starrag machine. Mr. Addy said that the earlier Scharmann Ecoforce HT2 with an integrated P600 face milling head was also used as a single-tool machine for large workpieces in the company’s other factory focused on heavy machining.
“We have proven the reliability of the Starrag machine tool and consistent high-quality machining results. In addition, we have always received excellent after-sales support and support from the company. Therefore, when we need to solve the flux demand of smaller valve bodies, continue A single source connection is totally meaningful,” Mr. Addy said.
The Heckert DBF machine tool has an integral U-axis, which is equipped with Starrag’s DBF multitasking head, which can perform various internal and external machining operations. The spindle head includes a panel with an integrated work spindle and CNC radial slide. In order to turn fixed workpieces, the rotary turning tool (with an axial runout of approximately 5 to 6 microns) can be adjusted radially by ±70 mm. In addition to external, internal and face turning, the head can also be conical and contour turning due to the NC axis of the radial sliding slider. For milling and drilling, the work spindle is placed in its center position.
Mr. Addy said that the workshop took full advantage of the machine’s 3500-rpm spindle, often using high-feed Capto cutters on carbon steel (WCB) at 850 rpm and 3000 mm/min feed speed. He continued: “This machine is indeed rigid. On softer materials, we are making incisions with a depth of 2 to 3 mm. For example, on a double body, we use a speed of 3 mm and a speed of 60 m/min. Feed speed for cutting. And 0.25 mm/rev. But this is a careful balance between depth of cut and speed and tool wear. Our goal is to maximize tool life. This is especially true when milling the rear of the flange, This operation can be particularly burdensome for the wear of the slitting saw used.”
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Post time: Feb-24-2021
