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Subcontracting of machining services for heavy machinery

Manufacturing of heavy process equipment requires extensive machinery and machine tools. Kumera retains massive machining capabilities, capacity to offer these services to partners and new customers alike, and resources to meet demanding challenges accordingly. Our array of five-axis floor type horizontal boring and milling machines are capable to work with the largest and heaviest parts up to 45 t in weight and dimensions up to 20 000 x 4000 x 4000 mm. For small and medium sized parts we offer precision five-axis machining by ultramodern high-speed machining centers.

Multi-axis machine tools not only make it possible to produce complex parts, such as turbines, bevel gears, and propellers, but also improve the efficiency and quality of conventional three-axis work: part turnings and setup times are greatly reduced. A workpiece is refined by our numerically controlled vertical lathes with rotary tools from a blank to an assembly-ready component. The largest lathe with a 25 t capacity in weight handles a workpiece with a maximum diameter of 4500 mm and height of 2000 mm.

Machinery for all purposes

The five-axis horizontal boring and milling machines are suitable for machining even the largest and heaviest parts (dimensions up to 20 000 x 4000 x 4000 mm, weight up to 45 t). The machines are equipped with automatic tool changers for shorter setup times. For small and medium sized parts there is precision five-axis machining in our recently installed high-speed machining center. This machine has a high level of built-in intelligence for automated work and independent decision making. For extremely long and heavy weight components (up to 26 000 mm of length and 200 t of weight), such as beams of industrial equipment, we have a floor-type horizontal boring and milling machine.

Benefits of five-axis machining

In multi-axis machining, the machine tool supports rotation around axes in addition to the basic translational movement along X, Y and Z. In five-axis machining, the rotation is possible around two of these axes. Rotation can be carried out by rotating the tool or the table. Multi-axis machines not only make it possible to produce complex parts, such as turbines, bevel gears, and propellers, but also improve the efficiency and quality of conventional three-axis work. Efficiency is improved due to the reduction in setup time. With a manually operated machine tool there is a need to turn a component to access its each side. A five-axis machine handles five sides of the part at once: for a six-sided part, only one turning is needed. A three-axis machine tool requires the same part to be turned five times. While setting up a part, the machine tool is not machining. A five-axis machine decreases the part's lead time considerably and makes production economically viable. Quality is improved due to increased precision and optimization of rake angles. A multi-axis machine allows the tools to move tangentially along a surface, so a better surface finish is achieved.

Vertical lathe – a comprehensive solution

Machining of heavy and asymmetric components is best suited for vertical lathes. A wide range of component sizes can be handled by our lathes. The largest lathe with 25 t capacity can handle a workpiece with a maximum diameter of 4500 mm and height of 2000 mm. The lathes are equipped with rotary tools, which make them capable of drilling holes and machining planar surfaces, such as grooves, in addition to the conventional turning operations. In fact, a numerically controlled vertical lathe with rotary tools refines a workpiece from a blank to an assembly-ready component completely on its own.

Advanced CNC programming

Heavy duty machining requires knowledgeable programming. Our skilled and painstaking CNC programming team is capable to work in both 3D and 2D environments and exploit the full potential of the modern five-axis machinery. Whether you deliver us a blueprint on paper or a CAD-model, we can handle it. The team is located in the same facility as the machinery, which allows them to maintain a continuous dialogue with the machine operators to guarantee flawless quality and production flow.

CERTIFIED QUALITY OF KUMERA MACHINERY

  • Kumera possesses an ASME U Stamp, which allows pressure vessel deliveries to, in the first place, the Americas.
  • Capable of PED (Pressure Equipment EU Directive (97/23/EC)) pressure equipment deliveries in the European Community in accordance with the module G (EC unit verification).
  • Capable of working under the rules and surveillance of maritime classification societies.
  • Certified to comply with the requirements of ISO 9001 Quality Management Systems, ISO 3834-2 Quality Requirements for fusion welding of metallic materials, and ISO 14001 Environmental Management Systems.