Metalworking operations

Precision metalworking is the cornerstone of Gusar's manufacturing technology and guarantees the consistent high quality of Gusar valves. In the manufacturing of simple and sophisticated parts alike, metal-cutting machines by leading European and Russian vendors are used.


Machinable parts and dimensions


Machine model

Part

Maximum dimensions, mm, L×B×H; Ø×L*

Maximum workpiece weight, kg

Axis positioning accuracy, mm

Trevisan horizontal milling machines with lathe machining functions

DS 300

Body parts (valve body, cap, etc.); rotating parts (gate valve coil, post, etc.), body parts of centrifugal horizontal pumps, filter parts, body parts of vacuum connectors, tooling of all kinds

600×500×600

900

0,02

DS 450

1000×800×900

1 500

0,02

DS 600 Niigata 80

1300×1000×1000

2 600

0,02

DS 900 Niigata 100

2500×1400×1600

6 000

0,02

DS 1200

3500×1800×2000

20 000

0,02

DS 1500

3800×2600×3700

25 000

0,02

Lathe machining centers with milling functions

Biglia

Rotating parts with surface grooves or openings

Ø315×1200

100

0,01–0,02

SNK EXL-80

Ø610×2700

2500

0,0150,02

SNK SLX-100×6000

Ø1000×6000

10000

0,0150,02

Turning and boring lathe machine

Wele VTC 2520-30

Rotating parts - high-pressure gate valve caps, adapter flanges, rail wheelsets

Ø3000×2000

22 000

0,02

Portal milling machining center

SNK RB-150F

(5-axial)

Box-like workpieces (e.g. cylinder blocks), drawing dies used in the manufacture of car body panels and similar parts, molds for die casting, aircraft wing section parts, turbine blades for gas turbine engines, impellers, etc., high precision machining of machine frames

3000×2000×600

10 000

0,0150,03

CNC lathes

Viper VT 30

Rotating parts with surface grooves or openings

Ø300×2550

1 400

0,04

Viper VT 40

Rotating parts

Ø400×3950

3 000

0,04

CNC surface grinding machines

Rosa Ermando linea platinum

Valve body, cap, or plate

3900×1500×550

4 000

0,03

Rosa Ermando linea gold

2000×1000×700

3 000

0,03

CNC milling machines

Wele 216

Valve body, cap, post or plate

2000×1500×1000

8 000

0,04

Wele321

3000×2000×1000

12 000

0,04

Wele421

4000×2000×1000

15 000

0,04


Machine models

Metal thickness, max, mm

Active zone, m

Plasma cutting

Plasma cutting machine with punch marking function

40

2×6



Biglia Smart Turn machining center



Smart Turn turn-milling machining centers by Biglia combine a lathe and a milling machining center. The machines have turn-milling units for efficient machining, automatic tool changer system, and a storage unit for 40 tools, which guarantees high production flexibility. Machines are designed for machining tasks of any complexity level with a single change of tools. The B axis unit, the increased Y axis stroke, and the built-in spindle motor support high performance machining of both hard and soft materials. The rigid frame design ensures the high machining accuracy. The machines have an anti-spindle allowing high-precision machining of parts in a single step.

Supported parts

Standard parts: shafts, pulleys, sleeves, bushings, flanges, compression flanges.

Custom and complex parts: wellhead seals, rotary wellhead seals, compact preventor parts, turbine impellers, pump impellers.

Spare parts for crushers: movable crushing cone, stationary crushing cone.


The machine supports all kinds of parts - from large-sized shafts with simple geometry to complex parts such as crankshafts.

Technical specifications:

Machinable bar diameter, max

85 mm

Turning diameter, max

500 mm

Turning length, max

1200 mm

Clamping diameter, max

310 mm

Hydraulic chuck (clamping force)

5-30 bar

Tool storage type/number of cells

chain/40 cells

Main spindle

Rotational speed

3000 rpm

Chuck diameter

315 mm

Anti-spindle

Rotational speed

4000 rpm

Chuck diameter

250 mm

Tool head

Rotational speed

5000 rpm

Tool holder

HSK-63

B axis travel

210 (+105/-105) deg

Minimum configurable value

0.001 deg

CNC system

FANUC Series 31i




SNK EXL-80 machining center


The innovative machines of the EXL series are designed for machining small series of workpieces with a complex geometry. Turn-milling machines simplify the machining process, reduce the cycle time and tool changes, making it possible to machine parts in a single step.

  • The high-strength turning spindle is driven by a powerful motor, and the milling spindle with a BT50 cone ensures high-quality workpiece machining and supports various types of operations.
  • The compact spindle head allows processing of workpieces with a complex geometry.
  • The lathe spindle rotates at up to 2000 rpm and is capable of machining workpieces, both small and large, at a high speed. 4 rectangular guides ensure high-speed and high-precision machining. In addition, the column travel system helps to ensure the high precision.

The machines are equipped with both a tailstock and an anti-spindle.

Supported parts

Standard parts: shafts, pulleys, sleeves, bushings, flanges, compression flanges.

Custom and complex parts: wellhead seals, rotary wellhead seals, compact preventor parts, turbine impellers, pump impellers.

Spare parts for crushers: movable crushing cone, stationary crushing cone.

The machine supports all kinds of parts - from large-sized shafts with simple geometry to complex parts such as crankshafts.

Technical specifications:

Machinable bar diameter, max

85 mm

Turning diameter, max

500 mm

Turning length, max

1200 mm

Clamping diameter, max

310 mm

Hydraulic chuck (clamping force)

5-30 bar

Tool storage type/number of cells

chain/40 cells

Main spindle

Rotational speed

3000 rpm

Chuck diameter

315 mm

Anti-spindle

Rotational speed

4000 rpm

Chuck diameter

250 mm

Tool head

Rotational speed

5000 rpm

Tool holder

HSK-63

B axis travel

210 (+105/-105) deg

Minimum configurable value

0.001 deg

CNC system

FANUC Series 31i



SNK SLX-100×6000 machining center


SNK SLX-100×6000.jpg

SLX is a large 5-axial turn-milling center, combining a horizontal milling machine with changeable attachment heads and a lathe. The SLX series is designed for efficiency and precision in multi-process machining.

Supported parts

The machine supports all kinds of parts - from large-sized shafts with simple geometry...

  • Turning diameter, max - 1000 mm
  • Workpiece length, max - 6000 mm
  • Max preloading weight - 10 tons

... to complex parts such as crankshafts.

Technical specifications:

Turning diameter, max

1000 mm

Turning length, max

6000 mm

Tailstock

yes

Clamping diameter,max

600 mm

Center-to-center distance

6492 mm

Maximum workpiece weight

10,000 kg

Rotational speed

1000 rpm

Rotational speed of the milling tool

4000 rpm

Axis travel:

X axis

850 mm

Y axis

-/+400 mm

Z axis

6500 mm

B axis

-/+90 deg

C axis

360 deg

Tool holder

ISO 50

CNC system

FANUC series 31i




SNK RB-150F machining center



This series is a successor to the successful RB series with 5-axial machining added to the classical portal design. The large travel along the X and Y axes supports machining of large and long workpieces.

  • The heavy-duty slider provides rigidity and machining precision.

  • The advanced 5-axial machining with full axis control allows workpiece machining from five sides.

Previously, milling of workpieces with an inclined surface, such as aircraft parts or rotors, required the use of special clamping devices, tools, and several machining steps. With their 5-axial control function, the RB-F machines do not require any additional equipment and perform consistently high-precision machining in a single step.

Supported parts

Shipbuilding and automotive industry

The cylinder block is the main and the most expensive part of the engine. It also forms the engine's frame, to which all other parts are attached. SNK RB-150F can machine cylinder blocks in a single step.

Manufacture of dies and molds

Manufacture of drawing dies, such as those used in the manufacture of car body panels and similar parts. Die casting molds.

Aircraft engineering

Aircraft wings section parts with side walls inclined at an angle to the base, requiring 5-axial machining and broad ranges of the machine's spindle speed. Parts of aircraft engines: turbine blades for gas turbine engines, impellers, etc.

Machine engineering

Precision machining of machine frames with a minimum number of process steps.

Technical specifications:

Working surface size

3000×1500 mm

Distance from table surface to spindle end

1200 mm

Table travel (X axis)

3250 mm

Spindle head travel (Y axis)

2400 mm

Spindle pin travel (Z axis)

600 mm

Arm travel (W axis)

600 mm

Spindle head tilt angle (B axis)

±95 °C

Spindle head rotation angle (C axis)

360 C

Maximum workpiece weight

10,000 kg

Spindle speed

40-6000 rpm

Spindle drive power

At low speed 22/18.5 kW

At high speed 30/25 kW



Wele VTC 2520-30, VTC 1616-20 machining centers



Wele VTC 2520-30, VTC 1616-20 machining centers

  • Double servo drives for arm travel along the W axis at a travel speed of up to 20 m/min.
  • The servo drives of the axes X, Z, and W have protective torque limiters.
  • The hydraulic balancer on the W axis locks the axis at full speed.
  • The arm with a clamping force of 18 tons has two hydraulic locking mechanisms on each side, designed for loads up to 4500 kg.
  • The table is supported by Wele's proprietary hydrostatic bearing integrated into the frame. The bearing is designed to withstand high loads and high cutting forces. Temperature expansion is minimized by the automatic oil temperature and pressure control system.
  • Specially designed tool storage: full-size coupling with an end gear for heavy-duty cutting modes, vertical automatic tool changer and spindle head changer, angular milling head with rigid engagement with built-in tool release mechanism for quick change of cutting tools, the tool clamping mechanism composed of 4 self-locking cylinders with hydraulic locking, improving clamping reliability and supporting heavy-duty cutting regimes.

Supported parts

Transitions (the entire part is machined in two steps):

  • concentric and eccentric transitions in large-diameter parts of various steel grades;

  • flanged transitions in steel.


Machining of hydrocyclone parts:

  • body liners;
  • lid liners;
  • cone liners (1st cone, 2nd cone, pre-cone).

Technical specifications:

VTC 252030

VTC 161620

Turning diameter, max

3000 mm

1600 mm

Turning length (height), max

2000 mm

1600 mm

Table rotation speed

140 rpm

260 rpm

Table torque

52,507 Nm

20,063 Nm

Table load

22,000 kg

14,000 kg

Milling tool motor (slider)

11 KW

11 KW

Milling spindle (slider) speed

1600 rpm

1600 rpm

Turning spindle cone

ISO 50

ISO 50

Accuracy

Positioning accuracy, axes X, Z (VDI)

0,02 mm

0,02 mm

Consistency, axes X, Z (VDI)

0,01 mm

0,01 mm

CNC system

FANUC 0 i

FANUC 0 i



Machining centers TREVISAN DS 300/70, 450/130, 600/200, 900/300, 1200/450, 1500/450c


  TREVISAN.JPG

The main distinguishing feature of TREVISAN's horizontal boring centers is the two independent spindles in the spindle unit.

The main spindle is designed for the main operations with a rotating tool: milling of planes and ledges, tapping, drilling and reaming.

Turning slide is designed for any operations based on turning: trimming of ends, external and internal turning, machining of external and internal grooves, thread cutting (incl. conical) with a chisel, rear flange trimming, chamfering. The main movement is the rotation of the tool with simultaneous programmable movement along the U axis, perpendicular to the rotation axis of the slide. The movement along the U axis is performed by an independent drive via the ball screw and guides.

The advantage of this machining method compared to a standard spindle is the fixed position of the workpiece during machining (and thus the machining precision does not depend on the workpiece weight).

This machining system ensures the stability of the cutting process, the absence of inertial forces that arise when the workpiece rotates, and the improved machining precision to +/- 0.010 mm.

The spindle unit has a main motor that rotated the main spindle and the slide.

An important advantage of this machine configuration is the minimized use of special tools (for complex internal surfaces) by programming the slide for various types of machining.

All machines have a angular milling head for milling of grooves.

Filter parts

Valve body parts weighing up to 20 tons at a high machining precision level.


Preventor parts for oil and gas wells, superdeep wells, and high pressure wells.


Purpose: well control equipment is used during operation and drilling, well repairs and wellhead pressure tests. It can effectively prevent oil, gas, and water show and ensure drilling safety.


Body parts of centrifugal horizontal pumps

Applications:

  • oil and gas industry,
  • chemical and petrochemical industry,
  • energy,
  • agrochemicals industry,
  • paper industry,
  • steel and electrometallurgical industry,
  • manufacturing industry.

Filter parts

Applications: gas, oil, chemical industries, heat supply systems, water supply systems and many other industries.


Body parts of vacuum connectors

Vacuum connector is a unit sealing the vacuum system, connecting its parts and external electrical or mechanical devices.

Trevisan machining centers are also capable of machining tools of any complexity level.

Technical specifications:

Trevisan machining center model, CNC Fanuc 31i

DS

300/70C

DS

450/130C

DS

600/200C

DS

900/300C

DS

1200/450C

DS

1500/450C

Boring spindle

Power

18 KW

22 KW

37 KW

37 KW

37 KW

37 KW

Rotation speed

2800 rpm

3000 rpm

2800 rpm

1500 rpm

1500 rpm

1000 rpm

Diameter

130 mm

130 mm

200 mm

240 mm

280 mm

280 mm

Programmable slide

U axis travel

70 mm

130 mm

200 mm

300 mm

450 mm

450 mm

Power

18 KW

22 KW

37 KW

37 KW

37 KW

37 KW

Rotation speed

750 rpm

550 rpm

450 rpm

150 rpm

100 rpm

100 rpm

Diameter

300 mm

450 mm

600 mm

900 mm

1200 mm

1500 mm

Max. machining diameter

350 mm

600 mm

850 mm

1400 mm

2000 mm

2350 mm

Axis travel

X

680 mm

1070 mm

1340 mm

2700 mm

3700 mm

4700 mm

Y

520 mm

800 mm

1000 mm

1440 mm

1900 mm

2400 mm

Z

600 mm

900 mm

1100 mm

1650 mm

2200 mm

3000 mm

Positioning accuracy

0,015 mm

0,015 mm

0,015 mm

0,015 mm

0,015 mm

0,015 mm

Consistency

0,005

0,005

0,005

0,005

0,005

0,005

Pallet system

2 units

2 units

2 units

2 units

Table

2 tables

Pallets size

600×600 mm

700×700 mm

900×900 mm

1250×1250 mm

2400×2400 mm

2400×2400 mm

Max. pallet load

900 kg

1500 kg

2600 kg

6000 kg

25,000 kg

25,000 kg

Tools

Max tool length

480 mm

520 mm

600 mm

800 mm

800 mm

800 mm

Max. tool weight

25 kg

30 kg

35 kg

60 kg

60 kg

60 kg

Store capacity

46 units

46 units

54 units

40 units

40 units

40 units



Control and measurement lab by Carl Zeiss*



Control and measurement lab Carl Zeiss MMZ M 30/45/20:

Measuring range:

X - 3000 mm

Y - 4500 mm

Z - 2000 mm

MPE error margin of length measurement - 3.3 μm

Carl Zeiss Contura 9/12/8 quality control center:

Measuring range:

X - 900 mm

Y - 1200 mm

Z - 800 mm

MPE error margin of length measurement - 1.8 μm



YASKAWA MOTOMAN robotic welding machine



1) Welding/overlaying of parts up to 1500 kg

(with the RSK welding manipulator);

2) Welding/overlaying of parts up to 15,000 kg without the use of rotary positioners

(using the shop console crane);

3) Overlaying of internal diameters:

  • diameters from 100 mm to 800 mm;
  • if there is access to the welding seam from both sides, from 100 mm to 1600 mm;

4) Welding of the following steels and alloys:

  • carbon steel,
  • low-alloy steel,
  • alloy steel,
  • high-alloy steel and superalloys,
  • corrosion-resistant steel and alloys,
  • heat-resistant steel and alloys.

5) Welding materials:

  • all-metal solid welding wire (diameters 0.8, 1.0, 1.2, 1.6 mm);
  • powder welding wire (diameters 0.8, 1.0, 1.2, 1.6 mm);
  • protective gas/mix (K2, K10, K18, K25, CO2, Ar).


Research Center


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The corporate research center features:


  • x-ray lab for large parts;
  • nondestructive test lab:
  • magnetic particle test lab;
  • ultrasound test lab;
  • liquid penetrant test lab;
  • radiation test lab.
  • destructive test lab:
  • environmental analysis lab;
  • chemical analysis lab;
  • test bench for large-sized pipeline valves;
  • coatings lab;
  • pumping equipment testing center;
  • custom products test lab;
  • Carl Zeiss quality control lab;
  • certification and standardization office.

Following studies are available:

  • determination of the chemical composition of metal products;
  • semiquantitative determination of the content of alloying elements in steels;
  • metallographic tests of metals;
  • mechanical tests of metals for tensile and impact bending performance (at ambient and negative temperatures down to -800 );
  • tests for resistance to intergranular corrosion;
  • determination of hardness by Brinell, Vickers, Micro-Vickers, and Rockwell;
  • tests of rolled metal and workpieces for impact strength using U (KSU) and V (KCV) concentrators;
  • tests of threaded connections with a test load;
  • high-precision measurements on measuring machines by Carl Zeiss.


Welding (overlay welding)


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The welding shop has the equipment and staff for the following operations:

  • manual metal arc cladding,
  • manual tungsten arc welding,
  • manual tungsten arc cladding,
  • machine metal active gas and mix welding,
  • machine metal active gas and mix cladding,
  • machine argon metal-arc welding,
  • machine argon metal-arc cladding
  • machine tubular-cored metal arc welding with active gas and mix shield,
  • machine tubular-cored metal arc cladding with active gas and mix shield,
  • machine tubular-cored metal arc welding with inert gas and mix shield,
  • machine tubular-cored metal arc cladding with inert gas and mix shield,
  • automatic submerged arc welding,
  • automatic tungsten arc welding,
  • automatic tungsten arc cladding,
  • automatic argon metal-arc welding,
  • automatic argon metal-arc cladding,
  • automatic metal active gas and mix welding,
  • automatic metal active gas and mix cladding,
  • automatic tubular-cored metal arc welding with active gas and mix shield,
  • automatic tubular-cored metal arc cladding with active gas and mix shield,
  • automatic tubular-cored metal arc welding with inert gas and mix shield,
  • automatic tubular-cored metal arc cladding with inert gas and mix shield.


Cornet LLC holds the welding permit for the following equipment groups at hazardous industrial facilities (NAKS certificate):

  • Oil and gas production equipment (NGDO) para. 8 (stop valves manufacture and factory repairs).

All operations are performed by certified high-qualified staff using certified, state-of-the-art equipment.


Contact person, machining

Oleg V. Kuklin

Tel. +7 (499) 553-00-33 [ext. 432], mob. +7 (929) 029-23-84