The selection of equipment was based on:

  • The material, dimensions, shape, and precision characteristics of the part being manufactured
  • The feasibility of processing modes with the applied tool
  • The size of allowances, shape, and precision characteristics of the initial blank
  • Methods for clamping and securing the blank on the machine
  • Ensuring the required production volumes
  • Automation of the manufacturing process
  • Reduction of processing time through the use of cutting tools with high-speed processing modes
  • Concentration of operations and transitions on a single machine
  • Analysis of cost-quality-capability parameters
  • Minimization of machine models

Thermochemical Spraying The process of thermochemical spraying with powder materials is designed to protect the surfaces of parts from corrosion, erosion, and high-temperature environmental effects, as well as to correct defects from mechanical processing. Thermochemical spraying of coatings is based on heating powder materials such as nickel, cobalt, chromium, and other substances in a high-temperature flame generated by the combustion of a propane-butane mixture or acetylene in oxygen. It is used for rapidly worn parts in the oil and drilling equipment, automotive machinery, textile production, shafts, rods, pump equipment sleeves, etc. It provides:

  • Creation of a hard, wear-resistant coating layer with a hardness of at least 55-58 HRC
  • Corrosion resistance of the treated part in aggressive environments
  • High erosion resistance
  • Correction of defects from mechanical processing

Spraying is performed using the “TENA” gas-flame spraying unit with carbide powder. This unit is designed for gas-flame spraying of carbide powders on the outer surfaces of cylindrical parts with a diameter of up to 110 mm and a length of up to 1500 mm, with a hardness of 56-62 HRC and a coating thickness of 0.2-0.5 mm. The application of this strengthening method increases the resistance of plungers in corrosive and abrasive environments and significantly extends the service life.   Surface Hardening by Nitrogen Ion Vacuum TreatmentNitrogen Ion Vacuum Hardening Nitrogen ion vacuum hardening is a modern, advanced method of surface hardening for parts. Cylinders and plungers of rod pumps operate in a complex multiphase environment (oil, water, sand, gases, etc.) with constant mechanical interactions during reciprocating movements. This is why oil field manufacturers require enhanced strength and wear resistance for these components. Process Essence Nitrogen ion vacuum hardening is a method with extensive technological capabilities, allowing for the creation of diffusion layers with the desired structure. The process of diffusion saturation is controlled and can be optimized according to specific technical requirements. By adjusting the composition of ionized gases and the intensity of the glow discharge, diffusion layers with an ion-phase (nitriding) zone or nitrided layers without a nitriding zone can be obtained. The nitriding zone is characterized by high density and strong adhesion to the base metal. The nitrogen ion vacuum hardening process overcomes previous limitations, allowing for the program-controlled nitriding of only the surface layer of the part, with a depth of 0.3-0.5 mm, achieving increased hardness in the range of HV 850-1200 kg/mm² (Vickers hardness). At AO “MUNAYMASH”, components and tools of appropriate dimensions from various industries can be subjected to nitrogen ion vacuum hardening, including:

  • Cylinders, plungers, shafts, axles, precision screws, spindles, tailstocks, and guides in machine engineering and petrochemical machinery
  • Extrusion screws, cylinders, and other plastic processing machine parts
  • Various types of gears for general machine engineering and the automotive industry
  • Forging dies and molds for metal and alloy casting
  • Cutting tools: mills, chisels, drills, etc.
  • Precision parts made from titanium alloys
  • Working surfaces of molds for forming elastomer products

GrindingGrinding of Steel, Nitrided, and Coated Surfaces
Performed on components such as shafts and plungers using cylindrical grinding machines.

  • Maximum length of the part: 2000 mm
  • Maximum diameter of the part: 150 mm

Roll Straightening:

  • Straightening accuracy over 1 meter length: 1 mm
  • Outer diameter of the workpiece up to 90 mm
  • Length of the workpiece up to 1 meter

Precision Tube Straightening with Outer Surface Control:

  • Straightening accuracy over 1 meter length: 0.05 mm
  • Outer diameter of the workpiece up to 120 mm
  • Length of the workpiece up to 6000 mm

Precision Tube Straightening with Active Control System for Deviations from the Straightness of the Inner Surface Axis:

  • Straightening accuracy over 1 meter length: 0.05 mm
  • Outer diameter of the workpiece up to 120 mm
  • Inner diameter of the workpiece: 44 – 70 mm
  • Length of the workpiece up to 6000 mm

Hydraulic Testing Each pump undergoes a leak test on specialized hydraulic test benches:

  • Working medium: Oil I-20A GOST 20799
  • Pressure: 25 MPa

Honing Performed on specialized machines, model RT 614, for processing long cylinders:

  • Length up to 6000 mm
  • Minimum diameter: 29 mm
  • Maximum diameter: 180 mm
  • Surface roughness up to 0.08
  • Straightness: 25 μm per 1000 mm, 60 μm over the entire length of the stroke

Boring of Long Cylinders Boring is performed on specialized machines, model RT 283233, for processing long cylinders:

  • Length up to 6000 mm
  • Minimum diameter: 29 mm
  • Maximum diameter: 180 mm
  • Surface roughness up to 0.63
  • Straightness: 24 μm per 1000 mm, 60 μm over the entire length of the stroke

Turning The available equipment allows for turning operations on parts, including cutting of conical and cylindrical threads:

  • Parts up to 9000 mm long
  • Maximum diameter: 120 mm

Hardinge GS 250 The GS series 2-axis lathes are compact and precise machines offering an excellent combination of standard features for this type of equipment. The GS lathes, equipped with a VDI turret and a powerful 3-jaw chuck, are capable of performing turning operations with milling for a variety of parts.   Nakamura-Tome SC-250Compact and High-Performance Lathe A compact and high-performance lathe with a wide range of standard features. The machine is manually assembled and equipped with robust sliding guides (box way) that ensure rigidity and precision during machining. It is well-suited for processing shafts and flanges.     Nakamura-Tome WT-300 A multifunctional lathe with 2 spindles and 2 turret heads. The machine features an exceptionally rigid construction with sliding guides on all axes. The high-speed and powerful spindle drive allows for simultaneous multitasking machining. In addition to its extensive mechanical processing capabilities, the independent dual-channel CNC integrates the potential of two machines into one. Thanks to precise synchronization of the spindle and sub-spindle rotations, as well as the ability to move the sub-spindle coaxially with the spindle axis, transferring the workpiece from the spindle chuck to the sub-spindle chuck for backside processing is done quickly and accurately without interrupting rotation. The low center of gravity reduces vibrations that affect machining accuracy and enhances the overall rigidity of the machine.   Romi G 50M Standard lathes for serial production with the capability to perform milling operations. These machines are characterized by high efficiency, precise machining, and substantial power. The construction of the lathes allows for the application of heavy cutting modes.   Nakamura-Tome Super NTJ A versatile dual-spindle turning and milling machine. This multifunctional turning and milling center features 2 spindles and 2 tool turrets. The upper turret can rotate around an axis perpendicular to the turret’s rotational axis (Axis B), allowing for contour milling in a single setup. Unique capabilities of the Nakamura-Tome multifunctional turning and milling center: The multifunctional machining centers can be equipped with:

  • A robot for loading and unloading workpieces or special tooling for loading and unloading parts, mounted on the turret.
  • A system for measuring finished parts.

The machine’s unique capabilities allow for:

  • Pressing bushings.
  • Programming automatic tool changes to a backup tool based on the maximum cutting force for that tool.
  • Drilling deep holes without a deep hole drilling cycle by programming periodic tool advancement based on cutting force.
  • Orienting the workpiece on the machine without the need for complex, expensive tooling.
  • Mounting a steady rest or center on the turret, which can be used as additional support during machining.
  • Minimizing the effects of tool holder collisions with the spindle due to operator error by controlling overloads in drives with the “Airbag” function.
  • Machining low-rigidity parts using a “vibration-free cutting” device, and more.

Nakamura-Tome Super NTJX A versatile dual-spindle turning and milling machine. This multifunctional turning and milling center features 2 spindles, 1 turret, and 1 tool (milling) spindle with automatic tool change. The ability to perform simultaneous machining operations on the workpiece using both the spindle and counter-spindle, with tools from the turret and tool spindle, significantly reduces machining cycles.     Nakamura-Tome machines are equipped with standard load monitoring devices on the axis drives. These devices implement the following functions:

  • Excess Load Detection (“Airbag”): This function helps prevent machine damage by detecting and mitigating collisions between machine mechanisms or between the machine and the workpiece due to programming or operator errors.
  • Load Monitoring During Drilling: Monitors and controls the load during drilling operations.
  • Workpiece Position Detection for “Non-Circular Shapes” (NT-Navigator): Assists in determining the position of workpieces that are not circular in shape on the machine.

Possible configurations for simultaneous machining of two different workpieces with multiple tools are provided below. Additionally, centers and steady rests can be mounted on the turret heads as additional support.