Turning the Tables in Heavy Production

As the oil and gas and power generation industries become more competitive, both OEMs and top tier equipment suppliers must constantly work smarter, quicker and more cost-effectively, investing in best-in-class manufacturing technologies that can meet market demands, achieve production savings and ensure their bottom-line margins are maintained or improved. For example, Burckhardt Compression AG (Winterthur, Switzerland) slashed their unproductive time in making piston compressors by using Dörries and Scharmann machines from the Starrag Group AG (Rorschacherberg, Switzerland) that are integrated with high levels of automation. To manufacture piston compressors that operate up to 3,600 bar, Burckhardt uses a Scharmann Alpha 1250 M machining center, a Scharmann Heavyspeed 2 ram-type boring mill, a Dörries Contumat VC 2400/200 vertical turning lathe (VTL) and a Scharmann Ecoforce 2 HT4 machining center to machine cylinders, cylinder blocks, frames, valve heads and steering rods.

Producing components up to 236 in long and weighing 66,139 lb, the production routines on these machines are demanding, including finish machining to 20 microns and H7 holes up to 51.2 in deep, but these machines consistently meet all of the requirements while generating time and production savings compared to former methods. “We gain extra benefits from using the additional moveable work table axis for set-up and/or in-situ workpiece inspection on the Dörries VTL,” explained August Dünki, the director of large part manufacturing at Burckhardt. “We also reduce unproductive time via the 72.4 hp Ecoforce 2 HT 4, which utilizes head attachments with automatic pick-up and robot tool handling.” Also important was the machine pre-approval software package that details workpiece processing, including all machining parameters, tools and targeted processing times. “This software is an important part of our machine selection,” added Dünki.

Mokveld Valves BV (Gouda, the Netherlands) reduces their long machining times, re-location errors and operating costs by producing high-pressure control and stop valves complete in a single set-up on an 80.5 hp Dörries Contumat VCE 2000 VTL. It machines and bores high-pressure axial flow control and stop valves measuring up to 94.5 in long by 78.7 in diameter and weighing up to 26,455 lb. These are produced from cast and chrome steels, duplex, super duplex Inconel and titanium, and 80 per cent of the machining – to finishes of 30 microns – is focused on turning. The use of a ‘second’ work table enables a workpiece to be set-up while another is being machined. One-hit machining also benefits KSB SE & Co. KGaA (Frankenthal, Germany), which minimized unproductive times and replaced two/three conventional machines with one Dörries Contumat VCE 2800/220 MC vertical lathe to produce pump housings weighing up to 6,614 lb to exacting IT6 tolerance standards.

Replacing a process that involved turning the front and rear sides of the housing on one machine, then re-locating the part on a different machine for drilling, KSB now uses the Contumat to perform all required tasks in a single clamping to reduce machining throughput times, increase operator utilization and improve operating profitability. In each of these examples, Starrag easily and cost-effectively modified and supplied each machine tool specifically to suit the unique machining needs of the user.

Starrag USA Inc., Skyport Business Park, 3279 Progress Drive, Hebron, KY 41048, 859-534-5201, [email protected], www.starrag.com.