Manufacturing the massive pumps used to bring oil and gas to the surface is not for the faint of heart in any respect. Made from thousands of pounds of alloy steel, stainless steel, cast iron and other difficult-to-machine materials, these industrial-strength pumps require extremely large diameter tooling, sometimes approaching 10 inches. Additionally, internal pockets, reservoirs and channels require extremely challenging long-reach milling and drilling operations. Clearly, when it comes to these large-diameter, long-length tools and tough part materials, not just any tool holder will do.
Pumps that leave the shop weighing 4,000 pounds typically start as 10,000-pound raw material blocks that take weeks or months to process. With such large amounts of material removal, tool wear is a major concern for shops in oil & gas pump production. Controlling and minimizing vibration, chatter and total indicated runout (TIR) are critical to these heavy-duty pump machining operations, especially in long-reach situations. Fortunately, the latest addition to the REGO-FIX powRgrip® (PG) toolholding system – PG 48 – is specifically designed for large diameter tools in aggressive machining applications.
The PG 48 tool holder accommodates cutters up to 40 mm (1.500”) in diameter and ensures total indicated runout (T.I.R.) of under 3 microns (0.0001”) for tool lengths up to 3xD.
Additionally, the holder provides length pre-adjustment with a repeat accuracy of less than 10 microns (0.0004”). Plus, it incorporates a special cap nut from the proven REGO-FIX secuRgrip tool locking system to effectively eliminate cutter pullout in heavy material removal applications.
The powRgrip system uses a taper-to-taper, press-fit collet holding design that creates a vibration-damping gap to interrupt the strength and severity of vibration waves. Three components make up the powRgrip system: holders, collets and press-fit assembly mounting units.
Because of its tool size capability, the PG 48 holders require the use of a brand-new press-fit assembly unit called the PGS 48. The PGS 48 is an automatic hydraulic press that generates up to 15 tons of force to press and remove collets from the holders and is a single-series machine designed only for PG 48.
Tool setting takes no more than 10 seconds without the use of heat or hydraulics as with other tool clamping systems. What’s more, powRgrip technology allows tools to be used immediately after the clamping cycle concludes without the limitations and tool-life compromises of other systems.
In addition to a pump’s main housing, a variety of other features must be machined, including hose fittings and connections, electrical boxes, valves and drive mechanisms. While these applications are not nearly as rigorous as the main pump body, TIR, rigidity and vibration damping are no less important. For these applications, the REGO-FIX standard powRgrip series provides the stability and vibration damping necessary for maximum tool life and improved surface finishes.
If you’re not familiar with the REGO-FIX PG toolholding system, click here to learn more. Better yet, you can try PG in a free trial. Follow this link to apply for your exclusive powRgrip test and trial to discover the industry’s most cost-effective and long-lasting toolholding systems that will help you get the most from your tools. Standard test and trials generally run three to four weeks and do not obligate you to any purchase. With REGO-FIX, you can always try before you buy.