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 888-628-5030sales@carmexusa.comwww.carmexusa.com

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