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.
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.
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 machines are equipped with both a tailstock and an anti-spindle.
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.
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.
The machine supports all kinds of parts - from large-sized shafts with simple geometry...
... to complex parts such as crankshafts.
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.
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.
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
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:
|
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 ñåðèè 0 i |
FANUC ñåðèè 0 i |
Machining centers TREVISAN DS 300/70ñ, 450/130ñ, 600/200ñ, 900/300ñ, 1200/450ñ, 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.
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:
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.
|
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 ìì |
0,005 ìì |
0,005 ìì |
0,005 ìì |
0,005 ìì |
0,005 ìì |
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:
4) Welding of the following steels and alloys:
5) Welding materials:
Research Center
The corporate research center features:
Following studies are available:
Welding (overlay welding)
The welding shop has the equipment and staff for the following operations:
Cornet LLC holds the welding permit for the following equipment groups at hazardous industrial facilities (NAKS certificate):
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