Well Ahead of the Game

Working in the oil and gas industry for 18 years, Wellahead Engineering Ltd. (Aberdeen, Scotland) invested in a DMU 95 monoBLOCK® universal milling machine from DMG MORI UK (Coventry, England) to offer a better service to their existing customers and be able to diversify into new energy and power generation markets. “We produce turnkey parts for downhole tools, wellhead and wireline equipment, working from concepts supplied by our customers,” explained Mike Coutts, the managing director of Wellahead. “We also offer made-to-order repair service. Investing in 5-axis machining enables us to be more competitive in our core business and gives us more opportunities in new markets. We are currently the only company north of Glasgow with this machine tool. We ran an open day for our customers and the response was really good, they welcome our new 5-axis capabilities. We anticipate that this machine will provide a big boost to our business.”

Previously, parts required several turning, milling and boring operations on different machines. The shop used two Maho MH800 machines for over 12 years and their reliability was second to none. So when the time came to invest, they wanted another quality machine tool. “Much of our work is cylindrical, so we specified a 26 in 3-jaw chuck that has enabled us to cut down considerably on the fixtures we use,” said Coutts. “This chuck, combined with the 5-axis capabilities of the machine, the Siemens control with its special technology cycles and the on-machine laser probe for tool setting, has enabled us to reduce our maximum number of operations down to two and halve our setting and programming times.” The DMU 95 monoBLOCK does all of this on one machine and has introduced new ideas for machining to the shop and new cycles to optimize productivity.

The rigidity of the machine is impressive. It is able to take full depth cuts with a 60 mm porcupine cutter with no vibration. The older machines would not have the torque necessary for such heavy cuts. “We are finding that not only is tool life longer, but we can also cut faster as well,” stated Coutts. “The high pressure coolant is excellent because the through-tool coolant can easily wash swarf out of deep holes.” One component with 12 holes previously took seven minutes to peck through each hole. But using the DMU 95 monoBLOCK all 12 holes were completed in only seven minutes with a U-drill straight through with no pecking. And it only used 11 percent of the machine’s power.

Wellahead employs highly skilled engineers and runs an apprentice program to build its workforce. Two of their engineers attended basic training for the DMU 95 monoBLOCK and then followed up with extra training. “All of our questions were answered. Nothing was left to figure out,” said Sam Morson, one of the trainees. “The after-sales support is good and the people we deal with are nice and competent.” The pre-installation machine tool checks were extensive and very thorough to make sure the shop was ready to take delivery, with sufficient access for delivery and with all of the services in place.

Wellahead Engineering Ltd., Unit 12, Kirkhill Pl, Kirkhill Industrial Estate, Dyce, Aberdeen AB21 0GU, Scotland, +44 1224 724478, www.wellaheadengineering.co.uk.

DMG MORI UK, 4030 Siskin Parkway East, Middlemarch Business Park, Coventry CV4 4PE, England, +44 2476 516137, Fax: +44 2476 516136, www.dmgmori.com.