As machine tool builders, we are continually targeting the design of our equipment to be aligned as well as possible with what industry needs. Many industries produce large valves and pumps and specific variations therein. A large quantity of these parts possesses similar features: flanges, holes, bores and internal threads. From a traditional machining point of view, these features are turned. That is, they are machined by rotating the workpiece and translating the cutter along a path that forms the appropriate geometry. Here are some examples:
Pumps & Valves Many of these parts, however, are non-round. Many cannot (safely) be held in a lathe due to part geometry. Furthermore, these parts require machining operations that are classical milling operations. Manufacturers have had to make these parts with the tools at hand. A most traditional solution is to use a horizontal boring mill for standard milled features and then attach a “facing head” for the bores, flanges and internal threads. While the part geometry can be formed, this method is highly unproductive:
The operation must be stopped for the milling attachment to installed by the operator
Tools must then be loaded by hand
Tools must be located before proceeding with the machining operation
The attachment doesn’t allow for through-tool coolant, which limits the chip load
Niigata developed a 2-pot Facing Head to make manufacturers as productive as possible. See how the facing head overcomes the inefficiencies:
The operation must be stopped for the milling attachment to installed by the operator
The standard ATC simply removes the CAT50 tool holder and installs a protective spindle cover, the Facing Head slides into position and the ATC then installs a turning tool holder. The operator never has to intervene.
Tools must then be loaded by hand
Once again, the tool simply changes from milling to turning
Tools must be located before proceeding with the machining operation
The tool is located before the machining cycles like any other tool
The attachment doesn’t allow for through-tool coolant, which limits the chip load
We can plumb coolant through the tool holder. Cool right?
To help understand the applicability of this tool on a specific part, consider the part below. There are four ports, each with a series of holes and flanges. In the first image, we illustrate a hidden edge view of the part. In the second, we generated a surface of those features that can now be machined using a Facing Head.
Solid Core – Machined Features using Facing Head To radically improve the productivity of your valves, pumps and fluid ends, please contact our Sales Team. You keep making these parts and we’ll keep finding ways to improve your operation.
For more information contact your Solution Providers– Premier Machine Tool – Sales 414-254-5150 / info@pmtmidwest.com
