“We were previously using two machines to complete the bodies,” continues Mr Addy. “A lathe to produce the flange and plug-way in three operations; then the part had to often queue for a separate operation (and additional set-up) on a drill, the final operation. 

“In needing to increase capacity, and with a good working relationship with Starrag, we had no hesitation in selecting the Heckert 630 DBF which offers a machining capability and specification that more than meets our needs for valve body machining: 630 mm by 630 mm pallets: X, Y and Z axis travels of 1,070 mm, 870 mm and 1,200 mm, respectively, and traverse speeds of 40, 40, 60 m/min in X, Y and Z; plus +/- 35 mm in the U (turning) axis; a 45 kW/1,700 Nm spindle.

“The DBF machine enables the production of complete body machining in one or two operations, depending on casting type and size,” says Mr Addy. The DBF strategy – for angle bodies in one-hit and for globe bodies in two operations of set-up for machining the plug-way (including drilling) then set-up and machine the flanges (including drilling) - has replaced a comparatively longer and laborious process of:

• Load to lathe
• Set-up and machine first flange 
• Set-up and machine second flange
• Set-up and machine the plug-way
• Move body to drilling cell
• Set-up and drill.

Mr Addy confirms that KOSO Kent Introl makes good use of the machine’s 45 kW, 3,500 rpm and 1,700 Nm torque spindle by, for example, often applying a high-feed Capto milling cutter on carbon steel (WCB) at speeds of 850 rpm and feeds of 3,000 mm/min.

He continues: “The machine is really rigid and on softer materials we are taking cuts of 2-3 mm deep – on Duplex bodies, for example, we’re taking 3 mm cuts at speeds and feeds of 60 m/min and 0.25 mm/rev. But it is a careful balance between cutting depths and speeds and tool wear; we aim to prolong tool life as much as we can. This is especially so when milling the rear of flanges – an operation that can be particularly onerous on the wear of the ‘slitting saws’ used.  

“In addition to working closely with Starrag on the initial fixturing, Starrag engineers also played a key role in helping us establish the DBF process(es) and programming,” says Mr Addy, “which meant the machine was immediately into production and saving us money.”