HELLER solutions at KSB
50% shorter machining time to produce fittings
The goal of KSB AG was to achieve a reduction in machining times. Considering the annual output of approx. 40,000 valve bodies, it required a highly productive and flexible concept to achieve this goal. The exchangeable out-facing head on the HELLER machining center model MCH 280 provided the solution. In addition to savings in machining time, it also allowed to achieve a significant reduction in set-up times.
Task
- drastically reduced working time alongside higher process reliability for fitting production
- universal machining center that offers sufficient stability for machining grey cast iron and ferrous metal castings
Project scope & solution
- the MCH 280 from HELLER with programmable U-axis and interchangeable facing heads
- integrated facing slide attachment with direct drive in the machine
- gear unit upgrade to 60 kW, required in particular for rolling
Result
- The MCH 280 is able to machine sealing flanges with just one cutting edge, which saves an enormous amount of time.
- The MCH 280 makes easy work of machining turning grooves, thanks to the freely programmable feed and facing slide attachment.
- facing slide for precise definition of the machining point on the cutting edge
- no collision contour, as the facing slide is coupled through the spindle center
- time required for the machining process reduced by 50% and faster setting, since one machine now handles all the tasks that previously required two machines
Customer testimonial
Roman Bertram
Head of Fitting Production at KSB
"[...] For us as machine builders, however, the solution where the shaft goes through the spindle center by means of a coupling unit, in other words via the tool fixture, was the safe bet. And this is important because we need a resilient machine that delivers the required level of process reliability."
More references
Peter Arnold
Head of Mechanical Manufacturing at Komax
"If you have to deal with 30 pallets containing, at times, up to 50 different clamping points per clamping cube, you need the right tools in the magazine to avoid having to constantly change the tool sets. Our tool count currently stands at 409. Comparable or smaller machines simply do not achieve capacities such as these."
Günter Muhr
Managing Director at Franz Haas Waffelmaschinen
"HELLER has exceeded our expectations. Everything went well, the machines run extremely reliably and our throughput times have also measurably reduced."
Thomas Kaysser
Managing Director at H.P. Kaysser
"Our experience with HELLER, including Service, has been nothing but positive. We speak the same language, so there was simply no reason to change supplier. The entire team has now identified with the HELLER machining centers – because they deliver what HELLER promises!"
Frank Brunner
Head of Manufacturing and Production Engineering at Bitzer
"For me, it was much more important to have found, in HELLER, a manufacturer whose machines are able to meet our high standards without extensive options."
Gerhard Aigner
Head of Production at Engel Austria
"We consider quality to be fundamental. The tolerances for our core components are between two and three hundredths of a millimeter. That's why we made the conscious decision to go for HELLER machines, which are renowned for their stability."
Nicholas Warnken
Nicholas Warnken, Project Manager
"Key contributors to these massive savings are fewer setups thanks to the 5th axis and higher achievable cutting parameters. On the other hand, however, it was the overall package, including the automation system and new tool technologies, that was able to optimize the processes in this way."
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