Gauteng-based Simmer Engineering have recently installed a new, large-capacity DN Solutions Puma VTR1620M ram type vertical borer that positions the company in the large component machining category. The machine was supplied by the Retecon Group company Puma Machine Tools.
“For such a large-capacity machine it occupies a relatively small area of shop floor space. That is because the focus of the machine is on height and weight rather than length. The machine has X axis travel of 2 220mm and a Y axis travel of 1 200mm, which gives you a maximum swing diameter of 2 100mm, a maximum turning diameter of 2 000mm and a workpiece height of 1 800mm. The live tools power is 35kW, the ram size is 260mm by 260mm, the spindle chuck diameter is 1 600mm and the spindle motor power is 75kW,” said John van der Merwe, CEO of Simmer Engineering.
“It is also equipped with a BT50 tool utilising a 50mm taper spindle, designed for high-torque, precision, and rigid cutting operations in industrial applications. The spindle (table) can be indexed in increments of 0.001 degrees (0.001° C-axis) for precise positioning while machining, drilling holes, milling, as well as heavy cutting.”
Gauteng-based Simmer Engineering have recently installed a new, large-capacity DN Solutions Puma VTR1620M ram type vertical borer that positions the company in the large component machining category. The machine was supplied by the Retecon Group company Puma Machine Tools. Machine shop manager Rudolph van Tonder gives an idea of the size of the machine
“All of these functions enable us to perform fast and highly accurate mill, drill and tap operations to be performed in one setup.”
“The vertical borer often gets mixed up with a vertical turning center. They are very similar but there are some key differences. A vertical lathe is equipped with a turret (often CNC) that allows for multiple tools, making it better for automation and complex, multi-operation jobs. It is best used for turning, facing, and boring, often with automated tool changes. The orientation of the machine is that it has a vertical spindle/table.”
“Whereas a vertical borer is a ram-type machine, traditionally designed for heavy-duty material removal, particularly for enlarging or finishing large, pre-existing holes (boring). It is best used for machining large-diameter, heavy workpieces requiring high precision and rigid cutting, such as large rings, flanges, or casings. The structure of the machine typically features a large rotating table and a bridge-type structure.”
Gravity does the work
“One of the biggest advantages of the vertical borer is that it uses gravity to set and hold a piece in place, reinforcing work holding security and process stability. In a vertical borer the workpiece weight is directed straight down into the machine foundation and produces no off-axis loads on the spindle.”
New machine, new client, new work. This component – a blower fan that weighs 950kg and has a diameter of 1 950mm – is part of a new order that Simmer Engineering has recently acquired
“The use of gravity also allows for lighter clamping pressures, greatly reducing the risk of damage when machining delicate pieces. With the high demand for vertical bored machined parts in the energy, mining, and construction industries, you’re ensured of a quick ROI for your business.”
“A key feature of the robust, ram-type machine, traditionally designed for heavy-duty material removal, is its ability for enlarging or finishing large, pre-existing holes (boring). It is designed for large-diameter, heavy workpieces requiring high precision and rigid cutting, such as large rings, flanges, or casings.”
“Typically, the machine features a large rotating table and a bridge-type structure.”
“The machine can accommodate workpieces up to 10 tons, which is a relatively small number in terms of weight. But if you think about it clearly there are not many workpieces that are in that weight category that require machining. It is more about the height of the component that is critical.”
“Besides we do not have the crane capacity to accommodate the very large castings.”
The machine has X axis travel of 2 220mm and a Y axis travel of 1 200mm, which gives you a maximum swing diameter of 2 100mm, a maximum turning diameter of 2 000mm and a workpiece height of 1 800mm
“When installed the machine weighs approximately 42 tons. To accommodate this, we had to make the foundations two metres deep and also allow for a pit so that the roller bearings, for example, can be serviced from beneath the machine.”
“The existing work that we have can keep the machine busy but we want to target the industries that require large castings to be machined. These are industries like power and mining. We have just signed a tender with Eskom and hopefully they are happy to give us more. I have planned a sales trip to the mining areas soon to introduce the new machine.”
“To give you an idea of the capability of the machine a pump casing can now be machined in two operations without any new setups as compared to three previously. We have cut down on the time to thread impellers by approximately 45% and even though the machining is being done on a more expensive machine we are realising huge cost savings for our clients.”
“The machine can accommodate workpieces up to 10 tons, which is a relatively small number in terms of weight. But if you think about it clearly there are not many workpieces that are in that weight category that require machining. It is more about the height of the component that is critical.”
“Once you see the fully extended ram – higher than most human beings – you get an idea of the large geometry of the component that can be machined.”
“We are always investing in new technology so we can be ahead of the competition. This machine has changed the game completely. To give you an idea on some of the other components that we machine on this machine, just by having the milling and drilling attachment and the driven tooling our on-time delivery has shot up by 97%.”
“Another example is a component that got setup on a conventional boring mill and it would take 90 to 120 minutes to do the turning and then we would have to set it up on a machining machine. The actual machining – drill and tap – would only take about 15 minutes but the setup time would be about 60 minutes.”
“Now we do the whole job of the same component in 25 minutes. Incredible time saving.”
CMM installation
“In keeping with our strict Quality Management System that has been developed to encompass industry standards and a wide range of approvals we invested in a precise shop floor CMM. The purchase of Aberlink’s Azimuth CNC CMM will now enhance the purchase of the DN Solutions Puma VTR1620M ram type vertical borer as the majority of the components that we will be targeting to machine will require CMM certification.”
Simmer Engineering invested in an Aberlink Azimuth CNC CMM that was installed in a purpose-built temperature-controlled room so as to offer clients a CMM service which is being called for regularly these days
“We specifically added CMM capabilities to our offerings because not many companies in our area of machining have CMM capabilities. This is a big advantage.”
For further details contact Simmer Engineering on TEL: 011 865 3403 or visit www.simmer.co.za
