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»We conducted benchmark tests with the machines and also investigated various add-on solutions using an infra-red interface supplied by tool manufacturers. Ultimately, we as machine builders considered this particular solution the safest option, since it provides coupling through the centre of the spindle by means of a coupling unit, i.e. the spindle taper. This is important because we need a robust machining centre which guarantees the necessary process dependability.« Roman Bertram, Head of Valve Manufacturing

Reducing machining time in valve production by 50%

HELLER solutions at KSB AG

Task Setting

  • Achieve a drastic reduction in machining time whilst increasing process dependability in valve manufacturing
  • Universal machining centre providing the appropriate stability for the machining of grey cast iron and ferrocast

Project scope and solution

  • HELLER MCH 280 with programmable U axis and exchangeable out-facing heads
  • Integrated out-facing slide with direct drive incorporated in the machine
  • Enhanced 60kW gear unit required for roller burnishing operations

Result

  • Sealing flange can be machined on MCH 280 using a single cutting edge resulting in significant time savings; in case of tool breakage only one indexable insert is affected instead of 12 cutting edges
  • Thanks to freely programmable feed and out-facing slide, machining of turned groove is possible on MCH 280 without any problem
  • Out-facing slide enables precise definition of cutting point on the cutting edge
  • No collision path due to coupling of out-facing slide through the centre of the spindle
  • Tool weights of up to 35kg with 50Nm tilting moment
  • 50% reduction in machining time and time savings in terms of setting operations, since all machining operations formerly accomplished on two machines can now be performed on a single machine
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