Turning face grooves on a Giddings
& Lewis horizontal boring mill with
integrated contouring head.
February 2015 | AdvancedManufacturing.org 55
Oil Parts Machining
Advanced Technologies for Machining Oil-Field Parts
Jim LorinczSenior Editor
New technologies offer heavy-duty
metal removal, reduced setup steps
and flexibility Despite falling oil prices, the investment valve in the oil
and gas industry remains on—for now—as manufac-
turers continue their race to provide large, precision
parts for fracking, subsea drilling and other related
activities. But as anybody in the energy sector knows: this is the
land of boom or bust. So when the going is good, the industry
can’t source pumps, drill bits and drilling equipment, tubular
stock, and valves fast enough. When it’s not, well, that’s when it
may be time to take stock of advanced machining technologies,
which may offer flexibility to diversify manufacturing operations
for another sector.
For now, the continued growth of hydraulic fracturing rermains
a force throughout the sector. Fracking has also brought hori-
zontal drilling with its increased demand for drilling tools into play.
Larger oil parts require larger machines, faster metal removal,
and, in the near future, may get an assist from the latest hybrid
subtractive/additive manufacturing technology.
Photo courtesy of Fives Giddings & Lewis
56 AdvancedManufacturing.org | February 2015
The challenge for job shops and OEMs alike is how to
machine larger workpieces faster with reduced or single set-
ups and with quicker changeovers for families of parts. And
if they can buy machines and equipment that have broader
use outside of oil and gas, that’s a bonus, too.
Here’s what you might expect to see.
Fracking Pumps: Workpieces as Large as Diesel Engine Blocks
According to Vince Trampus, vice president, Heller Machine
Tools (Troy, MI), pumps for the fracking industry start out as big
blocks of metal that are very similar to heavy-duty 11 to 16-L
diesel engine blocks for the trucking, construction and agricul-
ture industries. Heller’s H series horizontal machining cen-
ters—and before, that its MCH series HMCs—were developed
with the rigidity and power to machine cast iron and CGI diesel
engine blocks making Heller the leading supplier of machin-
ing centers to these industries. “Frack pumps begin as solid
blocks of alloy steel that weigh anywhere from 5000 to 8000 lb
[2268–3629 kg] and require removal of over 2000 lb [907 kg]
of metal during the machining process,” said Trampus.
“The question of how quickly that metal can be removed
is answered by the design of the H series HMCs, which are
extremely robust with a gear-driven headstock that delivers
full power at low rpms. We have four gear changes to get
up to an 8:1 ratio from the motor to the spindle resulting in
60 kW [@2292 N•m of torque] at the tool below 500 rpms,”
said Trampus.
“Fracking pump housings [typically made from 4340 alloy
steel with a hardness of 300 Brinnell] can be machined in
less than 20 hours using our H Series HMCs compared with
the 40–60 hours [or longer] in current machining processes
on multiple machines,” said Trampus.
“Unique to the industry, Heller’s feed out system [U axis]
on the H series allows the use of feed out tools required to
generate the finish tapered bores. The U axis is an NC-con-
trolled axis that enables feed out tools to be loaded auto-
matically into the spindle from the magazine vs.
the current process of manually loading tools onto
the quill spindle of a boring mill. These machine
features make Heller’s H series a perfect fit for
machining many types of energy business parts.”
Additive Manufacturing Poised for the Oilfield
The next big thing in the oilfield, according to
Dana Scott, general manager at Mazak’s South-
west Technology Center, could very well be hybrid
multitasking machine tools. Such technology com-
bines both additive and subtractive processes into
one machining center. “Right now components
that go downhole behind the drill bit have wear
pads on them, either made from titanium or Inco-
nel. The current process is for the OEM to send
the components out to have these wear pads or
wear rings welded on them.”
However, said Scott, a hybrid multitasking
machine such as Mazak’s new Integrex i-400AM
would allow shops to impart the titanium or Inco-
nel pads directly onto the existing components us-
ing the additive technology, then finish them with
conventional subtractive machining. “This would
eliminate the welding process and allow the com-
ponent to quickly go right to assembly,” he said.
“As with the wear pad components, the demand for
fracking tools 3½–6½" [89–165-mm] diameter in varying
lengths has also grown dramatically,” said Scott. Unique to
fracking are perforating guns and frack guns that fracture
Oil Parts Machining
Tri-cone PCD oil and gass drill bits with tungsen carbide for drilling holes
6–30" (152–762 mm) in diameter are machined in two operations on multi-
tasking machines such as Mazak’s Integrex e-670H that provides process-
ing flexibility while reducing shop time by more than a third when compared
with processing on conventional machines.
58 AdvancedManufacturing.org | February 2015
shale formations to release oil or gas. “Perforating guns,
which are 20' [6-m] long and about 4½" [114 mm] in diame-
ter, are used in multiples to blow through the well casing into
the rock formation, while frack guns, in multiple 3' [0.90-m]-
long sections, use ultra-high-pressure liquid and silicon to
fracture formations,” said Scott.
“Deep subsea drilling programs typically involve very
large parts like blowout preventers [BOP] that are up to 75'
[23-m] tall, valves and pumps of all
types, and big drill bits—parts that are
often processed on Mazak’s Integrex
e-670H Multi-Tasking Machine, for
instance,” said Scott. “Two different
types of drill bits are the single head
PCD drill bit that is 26" [660 mm] in
diameter and the tri cone bit with tung-
sten carbide that can drill holes 6–30"
[152–762 mm] in diameter. PCD drill
bits are machined in two operations
on the Integrex e-670H reducing shop
time by more than a third and provid-
ing agile production for low-volume
product mix compared with four or
five milling and turning operations on
conventional machines.”
One machine tool builder is also
exploring the potential for a large
premium-priced trunnion-style HMC
that has proven itself in machining
difficult-to-machine metals like Inconel
and titanium for aerospace applica-
tions. “The HU100-5X series machining
centers delivers 2000 ft-lb [2711 N•m]
of torque with a 10" [254-mm] face
mill and would be well-suited for faster
metal removal machining forged pump
housings. Also drill bits are getting larg-
er, reaching 40" [1016-mm] diameter,
making them well-suited for large meter
trunnion machining centers,” said Scott
Walker, president, Mitsui Seiki USA Inc.
(Franklin Lakes, NJ).
Changeover Versatility in Families
of Frack Pump Wear Parts
The ANW Series twin-spindle CNC
lathes from Fuji Machine America
(Vernon Hills, IL) feature the company’s
integrated Fuji-engineered robots and
workholding. The ANW Series is used
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See the FVL-1250VTC+C at Houstex. The FVL-1250VTC is perfect for heavy-duty turning applications. And with the optional live tooling function and the series offers additional flexible machining capabilities to make more complex workpieces with one machine.The cross-rail elevation system uses two large ballscrews for positioning and can be locked in any position with four independent hydraulic break systems. Result: The spindle RAM is able to more closely approach a workpiece, thus eliminating an overhang problem.The unique patent lock mechanism has eight hydraulic locking cylinders with curvic coupling to assure the turning holder is perfectly stationary on RAM. You get highly rigidity without vibration or cutting chatter. Plus no transfer of stress on the RAM spindle bearings, which substantially prolongs spindle life. It’s powerful. The enormous 60HP FANUC digital spindle motor, with a two-speed gearbox, generates up to 11,461Nm of torque in lower 37rpm. The optional Live Tooling models can easily handle up to M30 tap or 50mm drill with tough material.What does real POWER look like? Call your local dealer to see our comprehensive product line for all your machining needs. See you at Houstex.
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CMI_mfg_eng_FVL-1250VTC_half pg_4clr.indd 1 12/30/14 4:13 PM
Oil Parts Machining
February 2015 | AdvancedManufacturing.org 59
for precision machining of wear parts for couplings, well
service valves and valve seats, pump valves and seats, and
pistons and other parts to 20" (508-mm) diameter. Accord-
ing to Bill Gore, regional manager-North America, these
parts are typically made from metals
like 8620 alloy steel forgings or saw-
cut bar and have to meet the operat-
ing and performance requirements
associated with abrasive and corrosive
environments found in oil field and
fracking operations.
“One of the challenges that our oil field
customers face on a daily basis is the need to change over within
families of parts.”
“One of the challenges that our oil-
field customers face on a daily basis
is the need to change over within
families of parts. The ANW machines
are versatile and able to handle
changeover for families of parts, which
may consist of tris, quads, or quints,
fracking pumps with three, four, and
five pistons, in different diameters for
different sizes of valves and seats,”
said Gore.
“It isn’t unusual for end users to mix
and match different brands of com-
ponents based on their preferences.
They can change internal components
to match the different conditions of
fluids, media, and chemicals that they
are required to pump,” said Gore.
“For downhole applications, we have
developed a cell for turning the OD and
ID of popular 5½ and 7" [140, 178-mm]
semi-premium couplings. It features
an ANW 5000 twin-spindle horizontal
machine, with a lot of Z-axis travel
to machine both sides of the part.
Internally, there’s extra travel in the Z stroke to accommodate
long-reach boring bars. We leave the bore semi-finished
with enough stock so that they can be threaded on another
machine,” said Gore.
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60 AdvancedManufacturing.org | February 2015
Y-Axis for VTCs, Contouring
Head for Boring Mills, HMCs
Fives Giddings & Lewis LLC (Fond
du Lac, WI) has introduced a Y-axis
attachment that adds off-centerline
milling, drilling, and tapping capability to
vertical turning centers. The Y-axis at-
tachment combines a C-axis head with
table X and Z-axis motions, allowing
for single-setup processing of flanged
parts, pumps, housing and other energy
industry parts. “The Y-axis attachment
for vertical turning centers allows us to
provide capability to our customers that
would normally be done on a second-
ary operation on a horizontal machining
center or a boring mill,” said Pete Beyer,
director of product strategy and devel-
opment. “For large-part machining, it’s
Oil Parts Machining
Heller’s NC-controlled feed-out system uses an additional axis (U) to provide radial feed
movement of the tool cutting edge, reducing machining and idle times and improving
process dependability. The feed-out system is ideal for machining plane surfaces and
sealing surfaces, bores, contours of any kind, spherical segments and grooves.
62 AdvancedManufacturing.org | February 2015
always desirable to be able to machine the part complete on
one machine or in the least number of setups,” said Beyer.
“There is demand from the fracking segment for horizontal
boring mills and horizontal machining centers equipped with
another one of Fives’ recent developments, the Integrated
Contouring Head [ICH],” said Beyer. “Some customers are
interested in moving turning operations from a turning center
to a boring mill or a horizontal machining center with inte-
grated contouring head. If the percent-
age of turning versus milling is small or
the part is difficult to fixture or highly
unbalanced, it makes more sense to do
turning operations by spinning the tool
on a boring mill than by spinning the
part on a lathe,” said Beyer.
“Machining a forged steel main pump
housing, called a fluid end, that weighed
in at 10,000 lb [4536 kg], 3000 lb [1361
kg] of metal were roughed off in less
than 12 hours, holes bored with the live
spindle, and turning operations com-
pleted with the ICH,” said Beyer.
Recently Fives Giddings & Lewis
added a second extended-range ICH.
Rated at 56 kW, the extended-range
integrated contouring head handles
up to 980-mm ID and 780-mm OD. Its
U-axis slide stroke of 440 mm can pro-
duce small or large-diameter features in
a single setup without head changing
or operator intervention. It loads tools
via the machine’s ATC, which accom-
modates tools up to 609-mm long
weighing up to 18 kg.
Twin-Pallet HMCs Machine Precision Parts
Plano Machine & Instrument Inc.
(Gainesville, TX) has four Kitamura
HX-630i HMCs that are being used to
machine energy industry parts, princi-
pally for the fracking industry, as well
specialty parts for precision applica-
tions. “We’re primarily 75-80% energy
related,” said Billy D. Dennis, production
manager. “We machine a lot of internal
parts for frack pumps and families of
chrome moly parts, including bearing
retainers and connecting rods. With the
Kitamuras, which have twin oil-cooled
ballscrews and twin pallets, we are able
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Oil Parts Machining
February 2015 | AdvancedManufacturing.org 63
to get uptime well above 90% spindle utilization and accuracy
that is better than competitive brands,” said Dennis.
“Typical applications include bearing retainers and exit parts
that may require fourth-axis work or offset holes, and internal
grooves,” said Dennis. Parts are made predominantly from
chrome moly steels, 4140 steel casting for housings, as well
as 17/4 stainless steel, high nickel alloys, and some ductile
iron castings. We’re just getting set up on a new job, a ductile
iron casting, which is for a large mud pump. We also machine
parts for offshore seismic work, as well as some drilling rig
parts.” Specialty applications handled on the Kitamura HX-
630i HMCs include precision machining of a housing part for
a parabolic dish for a tracking device. Another specialty part is
used on a drilling mechanism that is used on a drill rig for dig-
ging bridge pilings used in the construction industry.
Heavy-Duty Machining for Large Energy Workpieces
Methods Machine Tools Inc. (Sudbury, MA) offers a range
of machines including the new Feeler SBM-2000 universal
milling machine, featuring extensive design and engineer-
ing by Methods to meet the oil-field industry requirement
for highly accurate machining of large heavy-duty parts
comprised of exotic materials. The SBM-2000 features an
articulated head and integrated fourth axis, eliminating the
need for multiple setups and operations.
“The SBM-2000 allows for a single setup for compli-
cated jobs by providing multi-angle and side machining
262-628-5030 or [email protected]
delivers a unique “ ” to small diameter thread milling cutters
• The Carmex “Helical Advantage™” for better overall performance in small cutting diameters
• Faster cutting action for higher production
• Spiral design reduces vibration and chatter
• Reduced cycle time
• Capacity for 1 to 3 inserts with unique clamping design
• Toolholders with internal coolant bore
Available in MT 7 Sub-Micron grade with TiAlN multi layered coating.
Contact your Carmex representative and add a new “twist” to your profitability.
Carmex’s NEW line of Mini Spiral Mill-Thread cutters offers:
The HU100-5X series machining centers delivers 2000 ft-lb (2711
N•m) of torque with a 10" (254-mm) face mill and would be well-
suited for faster metal removal machining forged pump housings.
Phot
o co
urte
sy M
itsui
Sei
ki
See us at HOUSTEX Booth #1629
64 AdvancedManufacturing.org | February 2015
capabilities for increased flexibility, machining efficiency and
cutting accuracy. A long 79" (2000-mm) X axis, combined
with a narrower Y axis and a bed positioned close to the
machine doors, provides easy access, further facilitating
flexible, fast setups. The vertical axis is counter-balanced
by a hydraulic cylinder, ensuring exceptional stability to the
milling head and the ram assembly,” said Dale Hedberg,
Feeler product manager at Methods.
“For large-part machining, it’s always desirable to be able to machine the
part complete on one machine or in the least number of setups.”
The Feeler SBM-2000 features a horizontal milling head
with spindle speed of 4000 rpm and has a 79 × 39" (2000
× 1000-mm) working area with a maximum table loading
capacity of 11,023 lb (5000 kg). It also offers an X-axis travel
of 79" (2000 mm), Y-axis travel of 47" (1200 mm), and a 39"
(1000 mm) Z-axis travel. A BT50 precision standard hori-
zontal spindle is driven by an AC servomotor via a two-step
transmission gearbox to supply high torque that provides
superb, heavy-duty cutting performance.
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Oil Parts Machining
?Fives Giddings & Lewis920-921-9400 / fivesgroup.com
Fuji Machine America Corp.847-821-2432 / fujimachine.com
Heller Machine Tools248-288-5000 / heller-machines.us
Kitamura Machinery of USA Inc.847-520-7755 / kitamura-machinery.com
Mazak Corp.859-342-1700 / mazakusa.com
Methods Machine Tools Inc.978-443-5388 / methodsmachine.com
Mitsui Seiki USA Inc.201-337-1300 / mitsuiseiki.com