Russian valve manufacturer has chosen a Doerries Scharmann multi-tasking vertical turning centre to replace two machining centres producing ball valve housings up to 4000mm diameter.
Doerries Scharmann Technologie is to build two large, 220 tonnes, multi-tasking, vertical turning lathes for the Russian company Penztyazhpromarmatura in Penza To carry out ‘one hit’ machining of the valves, the vertical turning centres (VTC) are fitted with a 37kW boring and milling unit and a high precision C-axis in the table
The VTCs also have a rotary table that can be moved in the Y-axis to allow longitudinal milling.
A magazine with automatic head changer provides universal and angled milling heads.
A 510mm long auxiliary spindle can also be fitted, as can an NC angled disc grinding head for awkward machining tasks on the valves.
The two machining centres feature identical technology but differ in terms of their machining diameter.
1 - Contumat VC 4000/350 MC V with 4000mm diameter capacity 2 - Contumat VC 3600/300 MC V with 3600mm diameter capacity.
For machining the large work pieces, one VCT will give more performance than three to four conventional machining centres.
This will bring the customer significant savings in time, operating personnel and costs, said DST.
DST added that Penztyazhpromarmatura has been using Doerries machine tools for more than 20 years and still operate with exemplary quality - one of the reasons for coming to DST again for the VCTs.
In the past, the standard solution was to use several machines with different cutting technologies.
However, this resulted in frequent changeovers of work pieces and a need to transport them between the various machines.
As a consequence, the company had to deal with reduced quality, high tooling times, considerable manpower requirements and, above all, low productivity.
The two VCTs will be installed at Penza in February or March 2009.
DST said that just transporting the machining centres to Penza, 700 km Southeast of Moscow, will take four weeks.
The machines will be dismantled and packaged for sea transportation.
Fully assembled, they have the impressive dimensions of 13 x 14.5 x 11m, said DST.
* About Penztyazhpromarmatura - Penztyazhpromarmatura has around 2,300 employees and mainly produces valves with a rated size of 50mm to 1,500mm (ID) for media such as gas, water, oil and chemicals.
The various media and applications in pipelines, power stations, chemical facilities and offshore installations call for materials that include cast metals, high and low alloy steel and titanium.
The different designs, for example, ball, flap, non-return and gate valves, are very accurate products.
The housings for ball valves, for example, can range up to 4000mm diameter.
The DST VTCs will reduce the current bottlenecks and problems to a minimum.
Each valve will be machined by just one Doerries VTC and only has to be set up once to complete all the machining operations.
The concept is based on vertical lathes, because most of the critical cutting operations involve turning.
* About DST - Doerries Scharmann Technologie is a 100% daughter company of the Vienna, Austria, based A-TEC Industries AG.
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