Product category:
Vertical machining centres (VMC)
News Release from: Cincinnati Machine | Subject: FTV 840/1800 machining centre
Edited by the Manufacturingtalk Editorial
Team on 02 November 2007
VMC reduces valve part machining time by
40%
Valve manufacturer reports that its latest vertical machining centre has machined a valve with 4,813 x 3mm diameter holes 40% quicker compared to the previous machine used for the task.
Koso Kent Introl (KKI) makes valves for environments and applications working at high pressure, high and sub zero temperatures, cavitation, flashing, erosion, solid contaminated fluids and high velocity and vibration To combat such hazardous use, KKI machines valves components in Inconel alloy, Hastelloy, Monel as well as in duplex, super duplex and 316 stainless steels
This article was originally published on Manufacturingtalk on 12 Mar 2003 at 8.00am (UK)
Related stories
Spring maker diversifies into CNC machining
The foresight to move into new products and new markets, based on acquisition of machining centres, has ensured the continued growth of a former spring maker.
Customised CNC with wizard screens used in VMCs
A customised CNC is believed the most user-friendly, reliable and highly specified CNC on the market, and is available with a range vertical machining centres.
Working such tough materials demanded a robust machining centre, which is why the company acquired a Cincinnati FTV 840/1800 model.
As part of the KOSO group of companies that specialise in the controls and process automation systems market, the West Yorkshire company has employed the FTV 840/1800 to run predominantly unmanned over two shifts.
KKI generally produces components with a maximum batch size of four.
Further reading
VMCs can be tailored for specific purposes
New cast iron structure features a range of vertical machining centres, available in four model designations and three performance packages, to tailor machines to different applications.
Five-axis VMCs feature high precision tilt head
A range of 5-axis fixed table VMCs has a high precision spindle head that features up to +/-95 deg tilt in the A-axis and full 360 deg contouring in the C-axis - ideal for machining complex parts.
VMC offers full 5-axis/5-sides machining
Vertical machining centre with a 5-axis rotary table comfortably machines workpieces up to 400mm in diameter and 300mm high, and has up to 150 deg tilt capability.
However, parts are complex and time consuming to manufacture, said Cincinnati to manufacturingtalk.com, and require extensive drilling, milling, slotting, thread milling and 4th axis drilling.
KKI production engineer Mr Paul Skitmore commented: "We reviewed the market and selected the FTV because it was the best machine available to suit our specific needs.
Machining difficult materials we needed something rigid, robust and above all reliable.
We were convinced by the build quality of the FTV and as we already have a Cincinnati machine that has been running without fault for over 12 years, reliability was never even a concern.
As each component requires a lot of machining we wanted to run our new machine unmanned through the night and the FTV allows us to do this." The company uses the 1.8m bed of the FTV to set up two parts simultaneously for unmanned 'lights out' running.
On one side of the bed is a dividing head and on the other side is a chuck that utilises the 4th axis function to carry out drilling operations on a PCD.
The company operates a morning and afternoon shift pattern and at the end of the afternoon shift the FTV is set with two parts that are machined overnight.
The valves and additional parts machined on the FTV often take up to 14h to machine due to the extensive drilling.
One part may require anything from 2000 to 4,500 holes.
Skitmore said: "The cylindrical valves can be anything from two to 16in diameter requiring thousands of holes from 3 to 6mm diameter drilled on the periphery.
We work up to 5-axis on the dividing head and this wasn't possible on our previous machine.
The FTV has increased our capabilities but most importantly it has given our productivity a major boost".
* Productivity gain - running the FTV unmanned, overnight, at KKI has given the company an average productivity gain of at least 30%.
Skitmore explained: "The FTV is a very rigid machine that immediately eliminates any vibration when machining and drilling, and this extends tool life considerably.
Added to this is the 6,000 rev/min spindle that allows us to run our drills faster than our other machines - to speeds suited to small drill diameters".
He added: "The rigidity and increased spindle speeds have significantly improved tool life and cycle times.
However, another major contributor to productivity and tool life gains is the high pressure through coolant facility.
The high pressure coolant delivers fluid directly to the contact point and this cools and maintains the sharp cutting edge whilst removing swarf from the work area".
An example of the productivity gains is one valve component, which has 4,813 x 3mm holes drilled in a super duplex SS part with a wall thickness of 16.5mm.
The time saving is over 40% compared to the previous machine used.
Skitmore said: "This productivity gain is due to the through coolant and faster spindle speeds that allow us to confidently machine components unmanned throughout the night".
Maintaining tool life and keeping a swarf free work area are essential aspects of 'lights out' machining, said Cincinnati to manufacturingtalk.com.
When a machine is cutting extremely difficult materials, as in the KKI machine shop, maintaining tool life and swarf clearance is critical.
The increased spindle speeds and direct coolant application have contributed to improved surface finishes and productivity considerably at KKI.
"The FTV has performed exceptionally well on some of the most difficult materials available.
The machine has served us well since its installation but what it gives us above all else is confidence that we can leave the machine when we go home at night and when we arrive the following morning, the parts will be completed without any scrap or reworking issues," concluded Skitmore.
* About KKI - originally formed under the name of Introl Limited in 1967, the now Koso Kent Introl Limited (KKI) of Brighouse is a manufacturer of standard and severe service control valves, chemical pumps and high technology surface choke valves for oil field applications.
Maintaining the highest standards of quality throughout design, production and customer service is the 'cornerstone' of KKI's philosophy and the company's plant is accredited in accordance with the ISO 9001 Quality Management System and ISO 14,001 Environmental Management System.
In addition all valves and parts where applicable conform to ATEX and PED industry standards and are CE marked accordingly.
Safety is the key element at KKI and it holds the Royal Society for Prevention of Accidents (ROSPA) silver award for occupational safety.
* About Cincinnati Machine - Cincinnati Machine Limited designs, builds and sources high-precision machine tools for the global aerospace, automotive, mould and die, medical and general machining markets.
The company offers tmachine tools and systems that include 3-, 4- and 5-axis CNC horizontal and vertical machining centres; and vertical, horizontal and multi-axis turning centres.
Cincinnati Machine is located in Birmingham, UK, and is a division focused on the design, development, sales and marketing of the Cincinnati range of machine tools.
Cincinnati Machine is a division within MAG Industrial Automation Systems, headquartered in Michigan, USA.
Other divisions within MAG IAS include the following.
* Cincinnati Technologies - serving the OEM and Tier 1 aerospace market.
* Powertrain Technologies - serving the global automotive market with customised high-production solutions.
* Maintenance Technologies - responsible for the global after-sales and service parts market for all MAG IAS customers.
• Cincinnati Machine: contact details and other news
• Email this article to a colleague
• Register for the free Manufacturingtalk email newsletter
• Manufacturingtalk Home Page
Search the Pro-Talk network of sites
