Those who had to deal with cutting pipelines, e.g. in industrial installations, need not be explained that this is a troublesome and expensive operation. Especially if we are dealing with a thick-walled pipe or when access is difficult. Further problems of classic pipe cutting are: the need for two cuts to compensate for the loss of length using the insert; keeping the cut perpendicular to the pipe axis; for large diameters even a small deviation is not allowed; potencjalna deformacja (owalizacja) rur cienkościennych, szczególnie dla dużych średnic; potential deformation (ovalization) of thin-walled pipes, especially frequent with large diameters.-the need to purchase an insert, which in the case of thick-walled pipes made of special alloy steel can significantly affect the downtime; significant cost of the insert; the need to chamfer four edges;two on the cut pipeline and two on the inset; the need to make two welds -time, costs and a problem with the location of new weldsin relation to other welds on the pipeline(maintaining a minimum distance-minimum sizes are usually defined by industry standards); introducing large amounts of heat, which may not be advisable in many cases. Most of these problems can be avoided by using lossless cutting with simultaneous chamfering by machining. The term “lossless” refers to the minimum length loss that would still be required for welding (“gap”). The cut / chamfer shape itself can be practically any, but three types of one-sided beveling are standard: V, Y and U, as well as beveling for narrow-gap joints. Ultimately, the shape of the bevel is decided by the welder, so it’s good if the welding documentation was prepared before cutting (in terms of bevel dimensions). The wall thickness of the pipe is practically not important. Despite the limited stroke of the tool post, it is possible to move the knife attachment point, which theoretically allows even cutting of full bars. The shape of the bevel is obtained by setting the knife in the cutter tool post or by using dedicated shape tools. Typical shapes of beveled edges airshow in the sketch below (note: the drawing is for illustration only and does not reflect the proportion of real cases): Typical bevel shapes for welding pipe edges. We currently have hydraulic cutters covering the full range of diameters -from 92.2 mm to 1240 mm. More about device sand cutting technology in the film: A set of cutters covering the full range of diameters. Adjustment of the connector length after fitting on the object. The necessity of dismantling and transporting elements from the object to the workshop was avoided. Application of the cutter in the factory. One avoids using a large stationary machine tool and all related activities. Cutting off the elbowing a horizontal section of a large diameter pipeline. Other application: turning the outer diameter of the culvert. The edge is ready for welding.
THE NEW WWTECH FACTORY PIEKOSZÓW
The construction of our new factory has started in Piekoszów. A modern production hall with technical and administrative facilities is being erected in the industrial zone, on a field of 2,5 ac in the new location, we intend to continue the activity related to the production of machine elements, spare parts and provide stationary machining services on a slightly larger scale. Until recently it was like this: Construction works are going very smoothly – as of November 20, 2019 and it will be in a few months:
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Where the scope is very non-standard, where the complex geometry of the object limits the freedom of machining using standard machines, there is a need to check the possibility of installing our equipment and then the possibility of machining. Due to this, we support us by 3D CAD technology, knowledge and software enabling the reproduction of an object and a machine in space, which allows, for example, the selection of a suitable machine, analysis of assembly options, control of possible collisions and even the design of a new machine matching the structure being machined. The latter case is not uncommon in the iron and steel industry and in hydro-power business. However, to be able to perform such simulations, we must start by making or selecting previously made 3D models. We currently have a faithful 3D representation of all our machines. The geometry of the object is a bigger problem – here a suitable 3D model is often used or the classic documentation is provided by the customer. Older objects often do not have any documentation, hence the need to create an additional 3D model. For this purpose, ordinary laser measurements are sometimes sufficient (article link: https://wwtech.com.pl/en/2019/03/18/the-workshop-metrology/), and sometimes 3D scanning of the structure of the object should be performed. The Faro Focus ™ device – a 3D laser scanner – is designed for this purpose. After further processing using a suitable program we get a ready model: In the next step, we add the machine model (s) to the structure model: Thanks to this, we can analyze the possibility of machining from all sides, excluding potential collisions or the inability to install the machine. Also thanks to this, we can optimize the implementation of the project, determining the possibilities of assembly and simultaneous operation of several machine tools. It often happens that a specific machine or at least a support structure must be designed for a specific task. Machines design: Other examples of 3D modeling applications: All of the above illustrations come from real projects implemented by WWtech.
Two hydraulic presses
Two hydraulic presses, one with horizontal axis and the other vertical. In both cases, we have milled the surfaces of the press tables. These two examples show that mobile machines can work in any position: horizontally, vertically or inverted. In the first case, the Laser Tracker ™ was also used to determine the machining geometry. In the second case, this was not necessary, as the task was a facing of the surface due to high post-operational wear
Fully functional equipment is fundamental to company’s success. Every machine has precision elements, bearings and number of other parts, that enable its efficient operation. Those main elements, which ensure correct machine operation require specific solutions in case of a breakdown. Leaks, cracks and grooves are issues that have to be eliminated to ensure proper operation.
An industrial metrology
WWTECH Company provides its clients with a complex way of problems resolving, offering them three-dimensional coordinate measurements and a full 3D documentation. Due to accurate measuring devices FARO (Laser Tracker, Measuring Arm) WWTECH makes it is possible to carry out uniquely accurate, fast and non-contact measurements, results of which can be analyzed in a real time.
In all undertaken activities WWTECH gives priority to the safety. Our staff’s and the society’s health, respect for the environment are the factors which determine a whole tam activities, a place and other aspects of our work, such as transportation or cooperation with a third party.
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