One-hit savings on oil & gas valves and fl uid ends

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energy

One-hit savings on oil & gas valves and fluid ends

The productivity benefits that oil and gas companies can gain by using Starrag’s Heckert DBF horizontal machining centres are unquestionable – thanks to the machines’ integral U axis that carries the Starrag DBF multitasking head, the rewards for one-hit, multi-facet, multi-face machining are unrivalled!

“ Whether you want a standalone solution or a highly automated one, the DBF series offers the highest throughputs with a superior surface fi nish and excellent precision.”

Doug Henderson, Vice President of Sales at Starrag US

The DBF spindle head comprises an integrated work spindle with CNC radial facing slide for the U-axis travel. For turning on a fi xed workpiece, the rotating turning tool – which has an axial runout of just fi ve/six microns – can be radially adjusted by +/- 35 mm. In addition to external, internal and face turning, the head also permits conical and contour turning courtesy of the radial facing slide’s NC axis. Unlike other U-axis tools add on units, the DBF provides 1,200 rpm, 45 kW of continuous power, and 1,700 Nm of continuous torque allowing the U-axis to effi ciently rough and finish features with a superior degree of accuracy.

For milling and drilling, the work spindle is arranged in the U-axis central position and is capable of delivery 3,500 rpm, 45 kW of continuous power, and 1,700 mm continuous torque. This allows the machine to perform effectively as a horizontal machining centre for roughing and fi nishing when the U-axis is not required.

77% reduction in cycle times

Utilising the DBF machines’ single set-up ability to mill, drill and turn fl uid ends, gate valves, drill bits and pump housings, for example, users have been able to slash machining times – in one instance, on control valves, from 20 hours to just 4.5 hours, achieving a 77% reduction in cycle times and a 95% reduction in overall processing times.

In a case, when the machine was complemented by a six-pallet linear storage system and 320-tool ATC storage, a DBF 1000 machining centre – ideal for fl uid ends due to their weight – runs unmanned and undertakes a non-stop routine of face milling using a 125 mm diameter cutter at a feed rate of 5,000 mm/min, end milling using a 50 mm diameter tool, solid drilling (70 mm diameter tool) then turning with an 89 mm diameter tooling and a 300 mm diameter external turning tool.

Accuracies of just 5 – 6 microns

The capabilities of the DBF machines’ axes offer unrivalled fl exibility in the machining of a multitude of facets – internal and external – on every face of a workpiece (except the clamping face), and with an axial runout accuracy of just 5 – 6 microns, all tolerance and concentricity values are consistently held, whatever the range and complexity of machining applications.

“Compared to other machines that may offer, say, facing head tooling via a toolchanger, the integrated DBF spindle utilises industry-standard tool holders such as HSK 100 and Capto, this allows DBF head users to buy standard tool holders to cover all turning sizes up to 500 mm versus an additional facing head being required for every 70 mm of travel.” says Starrag US Vice President of Sales, Doug Henderson.

“The result is that with the integrated U-axis, the tool tip is much closer to the spindle bearings and this leads to much more rigidity at the tool tip and therefore more accurate machining. Additionally, the integrated DBF spindle has the torque and power to maximise the machining process effi ciency”

DBF has replaced two roughing and one finishing machines

Doug Henderson adds: “And, of course, the DBF’s all-in-one process obviates the need (and expense) for separate roughing and fi nishing machines – in one case, a single DBF machine has replaced two 4-axis roughing machines and one 4-axis fi nishing machine – as well as the extra time and potential inaccuracies of workpiece re-location that accompany separate processes. It’s a perfect example of Starrag’s philosophy of ‘Engineering precisely what you value’. ”Whether stand alone or highly automated the Starrag DBF solutions provide the highest throughputs with superior surface fi nishes and excellent precision.

“Industrie 4.0” solutions with Starrag´s IPS

When applied in fully automated systems integrated by linear pallet systems and sophisticated, highly intelligent software routines to create high-performance manufacturing cells that boast maximum automation with minimal operator involvement. These “Industrie 4.0” solutions are ideally supported by Starrag´s IPS (Integrated Production System).

Another example – the production of fl uid ends which have average life cycles of 2,000/3,000 hours – sees a DBF model machining the ends from solid stainless steel blocks of four tonnes in just 32 hours instead of 50 hours. That’s a cycle time saving of 36%. The secret to the success of the Heckert DBF range of 5-axis machines (6-axis machining – without axis interpolation – when a tilting, NC rotary table is added, resulting in less complicated fi xturing) is the integral U-axis that carries the DBF machining head which allows both roughing and fi nishing on both the U-axis and the ‘standard’ horizontal spindle. Additionally, the machines offer an extended Z-axis travel to permit long-hole drilling as required in fluid ends, for example.

Combined, the capability of these axes therefore enable fl uid ends to be cost-effectively and effi ciently processed from roughing through to fi nishing. “Heavy metal” in sight: The new Heckert DBF 1000 machining centre is particularly suitable for highly efficient heavy-duty cutting of heavy housings weighing up to 4,000 kg, such as on the fluid ends.

Sabine Kerstan

Starrag Content Manager

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