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	0,015–0,02
	SNK SLX-100×6000		Ø1000×6000	10000	0,015–0,02
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	0,015–0,03
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

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 2520–30	VTC 1616–20
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 серии 0 i	FANUC серии 0 i

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

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 мм	0,005 мм	0,005 мм	0,005 мм	0,005 мм	0,005 мм
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

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 °С);
• 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)

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