PROVEN SOLUTIONS FLIUD END MACHINING FLUID END MACHINING PROVEN SOLUTIONS & TOOLING

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1 PROVEN SOLUTIONS FLIUD END MACHINING FLUID END MACHINING PROVEN SOLUTIONS & TOOLING

2 SECO PROVEN SOLUTIONS WILL IMPROVE YOUR PROCESS When you partner with Seco, our team of metalworking experts evaluate your processes and assist in determining the best possible solutions for your unique applications, whether those include standard or custom products. Across all industries and types of components, Seco provides the means for manufacturers to truly improve their productivity. Today, Seco employs nearly 5,000 employees across more than 45 countries and offers more than 30,000 standard products. Our superior product offering combined with the experience and expertise of Seco s metalworking specialists, enables us to provide the most advanced solutions for the machining of specialized components, setting us apart from our competition. Seco tooling and technical know-how equips our customers with the most economical and efficient process available. When it comes to purposespecific development of today s complex machining processes, look no further than Seco Proven Solutions. Seco s Component Engineered Tooling (CET) offers a comprehensive approach to process design and improvement that ensures you achieve the best possible results in your operations. CET provides extensive assistance in creating manufacturing processes to ensure the highest levels of productivity, efficiency and cost effectiveness. PROVEN SOLUTIONS FOR COMPONENT MACHINING With such a diverse and expansive catalog of products, Seco can optimize most operations with standard tooling. With the rapid and constant change of today s industry, though, sometimes your application demands something more. In these situations, our Custom Tooling program achieves the results you need. Our Custom Tooling team has extensive expertise in all major industry segments, including aerospace, automotive, oil and gas, medical and energy. Seco engineers work closely with your personnel to create a solution that will optimize your operations. From quotation to product delivery, Seco Custom Tooling excels in providing ideal results in minimal time, affording you the responsiveness needed to succeed in today s competitive market. While every application requires a specific solution, clear trends within various manufacturing industries have emerged over the past decade. These shifts have guided much of our research and development, leading to products that address industry-specific challenges. For more segment focused machining information, access our industry solutions area of the website, now featuring component machining animations, product info and more. 2

3 OUR FLUID END MACHINING EXPERTISE A fluid end is part of a high pressure hydraulic fracking operation, primarily for natural gas, where solution is pumped into the ground. These components are currently composed of solid 4340 and P20 billets, with newer designs being produced out of 15-5 and 17-4 stainless steels. Seco understands and provides tooling solutions designed to succeed in all materials and configurations specific to fluid end machining. These components undergo several machining operations to meet the high precision requirements of the finished product. PHASE 1: CUTTING & CUBING When the rough ingets arrive from the foundry, the first challenge is to square up the billets. This large cubing operation is an essential first step in preparing the stock for the rough machining phase. PHASE 2: ROUGH MACHINING In this phase, the squared billet is machined to the rough and semi-finished state. High metal removal and long deep holes are common challenges in this operation. The overall shape, port features and other details are machined to prepare the part for finish machining. PHASE 3: FINISH MACHINING The challenges in finish machining include high accuracy deep hole boring as well as threadmilling of large diameter acme and buttress threads. Process reliability and performance are important factors in this phase. 3

4 PHASE 1: CUTTING & CUBING PHASE The first task in machining a fluid end is to square off the steel billets that come from the foundry in a rough state. During the cubing phase, when the depth of cut may vary, it is important to have a cutter that can withstand the fluctuations during the operation. YOUR CHALLENGE Dealing with impurities in the steel, known as scale, on the surface of the billets combined with inconsistent depths of cut are the greatest challenges in this phase. Greater tool economy, product quality and higher metal removal rates are necessary to improve this process. OUR SOLUTION For productivity and economy, the choice is simple. The Double Octomill free cutting facemill from Seco provides high metal removal capabilities and consistent performance. The inserts have sixteen cutting edges and are securely mounted in the pocket, offering unsurpassed precision and economy. Double Octomill can withstand the fluctuations during the operation and leave a semi-finished surface before moving the the next phase. 4

5 RECOMMENDED TOOLING DOUBLE OCTOMILL CUBING DOUBLE OCTOMILL Objective Rough facing Material 4340 (Seco Material Group 4) Machine Niigata HN100 Cutter R M No. of teeth 20 No cutting edges 16 Insert ONMU090520ANTN-MD17 MP2500 vc 650 sfpm n 414 rpm Cutting fz.012 data vf 99 ipm ap 4.2 ae.150 Result Quiet machining with superior performance in variable depth machining passes. Superior tool life per edge. The next generation Double Octomill R face milling cutter is a highly versatile, economical and productive tool that can be used for both roughing and finishing. A unique feature that sets Double octomill apart from ordinary face mills is its precision insert seating technology. A set of hardened HSS pins in each insert pocket locate the insert securely and accurately making it easy to index them and eliminating the need for any axial adjustment. What s more, the 65 Hrc pins ensure an extremely long life for the pocket. For this specific application, the Double Octomill, with its 16 cutting edges and positive insert geometry, can make a unique contribution to milling performance. EXCELLENT PRECISION RADIAL AND AXIAL RUNOUT Radial and axial supports Location pin HSS Bottom support surface UNBEATABLY LOW COST PER EDGE The next generation Double Octomill face milling cutter is an excellent choice for general applications in cast iron, steel and stainless steel in a wide range of industries. With 16 cutting edges it offers unmatched economy in terms of edge cost per insert. This, in turn, gives lower component cost. BOOST YOUR PRODUCTIVITY AND CUT YOUR OPERATING COSTS Why choose Double Octomill? Same tool for roughing and finishing Excellent surface finish Long tool life Light cutting action Fewer spare parts, easy handling 5

6 PHASE 2: ROUGH MACHINING The rough machining phase is all about metal removal and deep hole drilling. Fluid ends are machined from solid billets of steel and approximately 40% of the material gets removed in this process. YOUR CHALLENGE In this step, the challenge is metal removal, often requiring long gauge lengths in interrupted cuts. High metal removal rates and tool stability is a must, especially in long reach drilling and milling operations. OUR SOLUTION Seco has the solution to this massive task starting with our comprehensive line of high feed milling cutters, designed to give the customer the highest amount of metal removal possible. Our Steadyline tool holding system provides excellent stability in long reach applications. For the long through hole in the fluid ends, Seco has developed a deep hole drilling concept to be able to drill up to 30 inches in depth. This is capable with the combination of a special fluted holder with a modified modular Perfomax drill head, optimized for deep hole drilling. Our Perfomax modular drilling system provides an inserted carbide solution with the best performance and economy available. For machining the scalloped clearance feature around the mounting holes, Seco offers special disc milling cutters that can be specifically designed to fit the customers needs. These challenging features on fluid end components can be handled with maximum performance and economy with our disc mills. 6

7 RECOMMENDED TOOLING PERFOMAX MODULAR DRILL FOR HIGH METAL REMOVAL SD600 is a modular drill system specifically designed for applications that require large and deep holes to be drilled with safety and efficiency. Large components in the oil & gas and power generation industries often require flexible and modular solutions. The SD600 drill modularity provides this flexibility and allows for a wide range of adjustments. HIGH FEED MILLING FOR MAXIMUM METAL REMOVAL R high feed milling cutters are designed for maximum metal removal and stability. Whether it is high feed face milling or helical interpolation to rough bore, these cutters will reduce cycle time. STEADYLINE TOOLHOLDER FOR SECURE TOOLHOLDING Steadyline holders drastically improve the dynamic rigidity of milling assemblies. This allows much higher cutting conditions, with quieter operation and optimum stability. THREADMILLING FOR PRECISE THREAD FORMING (FINISHING) Seco has engineered a range of tool holders with multi-tooth cutter bodies for O.D. and I.D. thread making operations. Unlike tapping, milled threads can be machined to full depth, even in materials that have already been hardened, with no sacrifice to the thread form, surface finish or accuracy. LONG REACH HOLDER FOR MAXIMUM FLOW For the long through hole in the fluid ends, Seco has developed a deep hole drilling concept, like an auger, to be able to drill up to 30 inches in depth. DISC MILLING FOR MULTITASK OPERATIONS Our component engineered disc mills show our custom tooling expertise to meet our customers demands. Our disc mills combine reliability and performance to give you the edge in cycle time reduction. 7

8 RECOMMENDED TOOLING CUSTOM HIGH FEED MILL FOR MAXIMUM METAL REMOVAL Our newly deveoped high feed cutter was made specifically for the demands of fluid end machining and is ideal for long reach applications at high feed rates. With differential pitch and added flutes, these cutters are engineered to maintain process reliability and productivity in long gauge lengths. An ideal tool for helical interpolation of large bore diameters and high metal removal rates in facing operations. FLUID END HIGH FEED MACHINING Material 4340 (Seco Material Group 4) Cutter 2 diff pitch high feed, R R160.5A Insert Qty 5, T-04 MD09 MP3000 Machine Niigata HN100 RPM 763 SFPM 400 /121.9 meters Cutting fz.050"/1.27 mm data vf 210" solid / 155" interupted ap.025" per revolution/.635mm ae 3.68" min bore dia./93.47mm Operation Interpolation of bores Result Ran with a 15 gauge length, interpolating out bores on 4340 fluid ends. STEADYLINE VIBRATION DAMENPING SYSTEM FOR CHATTER-FREE CUTTING When dealing with long overhangs in milling, like what you find in fluid end machining, there is one major problem vibration. Usually the method to reduce vibrations in these situations is to slow down your operating parameters. The problem with this is the loss of productivity and also reduction in tool life. Also, with vibration you have problems with noise and the negative effects on the machine tools spindle. To combat these problems Seco offers Steadyline, a patented, passive dynamic vibration damping shell mill holder system that drastically improves rigidity of milling assemblies. Steadyline allows for much higher cutting conditions which increases productivity. Steadyline also provides improved surface finish combined with longer tool and machine spindle life. You also have a much quieter shop which will be very positive for your employees and machines alike! competitor Steadyline Stability without damped tool holder Stability with Steadyline With the vibration absorber: vibration is eliminated. Stable depth, inch Without the absorber: vibration spreads through the holder. Spindle speed, rpm 8

9 PERFOMAX MODULAR DRILL & LONG REACH HOLDER FOR HIGH METAL REMOVAL The new design of the SD609 Modular drill head, has been optimized specifically for machining fluid end components. Advantages: Adjustable setting length of pilot drill Optimized chip flutes Guide pads optimized for 3-point contact Insert cartridges Strong square inserts and pilot drill The special holder is made in a high tensile tool steel with a chrome plating of 70 HRC in hardness to protect the holder from wear, and to ensure a long tool life of the holder. For application security, the holder has a unique design of the chip flutes ensuring best possible chip evacuation. FLUID END PERFOMAX MODULAR DRILL Material 4340 Hrc (Seco Material Group 5) Drill SD RG Insert SCGX09T308-P1 & SCGX P1, T3000D Pilot drill SD R Extension M (L = 9.8 ) Machine Large Machining Center CAT50 taper, 42 hp Drilling depth 12.0 Inch blind hole Cutting vc 324 sfpm data n 354 rpm f.006 ipr vf 2.01 IPM Coolant Internal coolant (120 PSI) No existing pre-hole or centering Result Consistent and reliable tool life 10 holes (One Fluid End) completed without reaching tool life limits FLUID END MAXIMUM FLOW HOLDER Material 4340 Hrc (Seco Material Group 5) Drill SD Insert SCGX09/12-P2 T400D Pilot drill SD R-US Holder Special fluted holder CAT50 L = 27.5 Machine Large Machining Center CAT50, 50 hp Drilling depth 28.5 Inch through hole (57 Inch tot) Cutting vc 200 sfpm data n 220 rpm f.006 ipr vf 1.3 IPM Coolant 1000 PSI Result Enter and breaking through the hole with 50% feed/rev Total drill depth 57, drilled from both sides DISC MILLING FOR MULTITASK OPERATIONS Our special disc mills offer superior performance custom designed to meet your specific needs. Our disc mills utilize Seco s standard insert geometries and give flexibility in machining the scallop feature on the fluid end. Our newest design has excellent spacing for chip evacuation, through the spindle coolant capabilities and is designed to be the most stable and productive tool available. Features: Decreased vibrations and improved surface finish Utilizes standard Seco inserts Reduction in cycle time Engineered to increase performance and productivity 9

10 PHASE 3: FINISH MACHINING The finish machining phase is the most critical part of the process. For fluid end machining roughing, semi finishing and finishing of the holes is an important and costly process. Having productive boring tools that can do each stage is important for reliability of the process and reducing costs. This stage also includes the threading operation which is the last step on the component. If there is any error in generating the thread profile, the part would need to be scrapped, resulting in a significant cost. YOUR CHALLENGE Process stability and accuracy are critical in all machining processes of a fluid end but especially so in the finishing operations. Precise threading and boring applications can be time consuming so the most accurate and productive tooling is necessary. OUR SOLUTION All of Seco boring heads use the patented Graflex connection. This rigid and accurate connection allows you to add extension for long reach application. Now available, is the option to have A750 and A780 heads with Seco Capto connections. This gives your shop more options to use Seco boring systems directly in multitasking machines. For making threads, we have recently developed a new spiral indexable threadmill, designed specifically for finishing fluid end components. With the accuracy of the thread profile form and secure holding of the insert, you can be confident that the thread form will be achieved consistently every time. 10

11 RECOMMENDED TOOLING THREADMILLING AMERICAN BUTTRESS THREAD PROFILE FOR THREAD PROFILING Seco s technical expertise and experience in fluid end machining allows us to develop high performance tooling specific to this industry. This new spiral indexable threadmill was designed specifically for finishing fluid end components. This new tool enables a smooth threading operation at high feed rates. Features of new designed threadmill for American Buttress thread form Eight inserts in cutter for faster cutting and reduced cycle time Rigid clamp to hold insert securely resulting in better gauging of thread Helical design to reduce cutting tool pressure which reduces chatter and produce precision thread form Better Chip evacuation Less horsepower consumption High accuracy ground thread form on indexable insert Superior consistent substrate and grade for indexable threading GRAFLEX TWIN BORE & LITELINE HOLDER FOR HIGH METAL REMOVAL For semi finishing Seco offers the A750 twin bore roughing head. The A750 is designed for high metal removal and is designed for symmetrical or staggered operation and setting. The A750 has the ability to use both 80 and 90 degree lead angle inserts and also the ability to hold double sided negative inserts. For finishing of holes where tighter tolerance may be required Seco offers two single tooth finishing heads. The A780 and A790 finishing heads allow an IT5 hole tolerance due to the micrometer adjustment. Not only are these systems accurate they are rigid due to the insert being in contact with the body. The A780 is a non balancable type head for lower speeds. When higher speeds are needed or you have long overhangs or both conditions at the same time the balancable A790 is a great option. When using large finishing heads with extensions, weight can become an issue for the operator and machine tool. To solve this issue Seco offers Liteline. Liteline is our A780 finish heads and extensions made out of aluminum. With Liteline you can have up to 60% weight reduction over a comparable steel set up. CONTACT YOUR SECO TECHNICAL SPECIALIST FOR MORE INFORMATION ON A COMPLETE MACHINING PROCESS & QUOTE, OR FOR INDIVIDUAL CUSTOM TOOLING OPPORTUNITIES. 11

12 Follow Seco Tools on Twitter, Facebook, LinkedIn and YouTube and stay up to date on new products and technology, special events, trade shows, special promotions and more. Cutting Edge Conversation Blog: cuttingedgeconversation.blogspot.com/ Product videos: To find an Authorized SECO Distributor near you, please refer to the Distributor Locator on our website: For technical assistance, call: Bellingham Drive, Troy, MI P Copyright 2012 Seco Tools Inc. GT Printed in USA. All rights reserved.