A technology concentrate !
NEWEN® CONTOUR-BB™ : 2-Axis Single Point CNC Valve Seat & Guide Machine.
NEWEN FIXED-TURNING® MACHINING PROCESS (PATENTED)
- Max X-Axis Travel 760mm (29.92”)
- Max Y-Axis Travel 60mm (2.36”)
- Max Z-Axis Travel 250mm (9.84”)
CYLINDER HEAD DIMENSIONS
- Maximum height (w/o removing pilot) 315mm (12.40”)
- Maximum length unlimited
- Maximum width Approx. 450mm (17.72”)
The Benefits of Coolant
The reaming of valve guides with piloted NEWEN reamers guaranties their perfect calibration. The high output filtrated cutting-fluid plays three (3) essential roles in obtaining the best reaming results:
1) The cutting fluid is forced through by the custom flutes of the NEWEN reamers acting like pumps. The forced flow of the cutting lubricant pushes the shavings towards the outside of the valve guide, thus allowing a perfect calibration. The reamer does not risk wearing because of the shavings that would otherwise work their way back up into the guide.
2) The efficient cooling off of the reamer and of the valve guide prevents the expansion of these two parts that are a source of diameter differences and calibration defects such as, among others, cylindricity defects.
3) The 10 micron filtration and the settling stages of the cooling liquid eliminate all the shavings that would interpose between the guide and the reamer and would provoke surface finish defects.
All the valve seats can be machined with the new carbide, ceramics
or CBN cutters which are all coated with numerous layers of materials very resistant to wear. These cutters, developed for numerically controlled machining in the general mechanical industry, are inexpensive and their effectiveness is often multiplied by the spraying of a cutting oil that, while protecting the cutting edges, prevents the metal shavings from sticking to the tool.
Light materials such as aluminum and bronze beryllium are machined economically and with precision owing to tooling coolant spraying. The tools lives are multiplied and the surface finish qualities are greatly improved.
The finishing passes in all materials benefit from the absence of havings sticking and yield impeccable surface finishes while sparing the cutting edges of the cutter.
VALVE SEATS HOUSINGS
The precision machining of valve seat housings and, in particular, in aluminum cylinder heads, depends in large part on an abundant watering of the actual machining operation. The geometric qualities of the housing, such as its cylindricity, the flatness of the valve seat resting surface, the perpendicularity between the housing and the valve seat resting surface, are guaranteed by the very principle of the FIXED-TURNING® process.
These qualities guaranty that the valve seats that will be installed within said housings will be perfectly held in their respective housing and will not move. Likewise, the thermal exchanges will be optimized, which is of the utmost importance for valve seats installed in natural gas engines.
A machining operation carried out on a “CS” version machine will allow to guaranty precise dimensions, while keeping metal shavings from sticking to the cutting tool which invariably translates into an uncontrolled wear of the cutting edges of the tool and machining dimensions more or less uncertain. The surface finishes also are, by the same token, greatly improved. More precision in the machining of valve seat housings allows to reduce the “press fit” in all safety and thus to considerably improve the work quality and the reliability of the engine.
A faster production, more precise and with a lower cost, and a first rate quality job.
WHY ARE CUTTING TOOLS WEARING PREMATURELY ?
If the tip-holder is damaged, the cutting tools cannot resist and get destroyed very rapidly. It is not actual tool wear but inevitable destruction of the tool’s cutting edge as the tool enters and exits the material too frequently. Hence, in this case, one must first check the tool holder and replace it on a regular basis!
The abnormal wear of the tip-holders comes from:
1. actual tool crashes
2. cutting tools tightened on dirty surfaces (metal shavings, dirt, etc...)
3. mounting non conforming cutting tools, “cheap” tools with tolerances that go with their price. NEWEN cutting tools are guarantied at + or - .02mm; cheap cutting tools range up to + or - 0.08mm. Or even worse, mounting “approaching” cutting tools with dimensions in inches. If one mounts NEWEN cutting tools and verifies that the housing is clean prior to acutally mounting the cutting tool, the tip-holder shall serve and remain operational for several years (2 or 3, not 10!).
Again, coolant is used to keep shavings from sticking to the cutting edges. Sticking leads to the destruction of said edges that are subjected to enormous pressures because it is the material that is sticking to the tools’ edges that is becoming an actual cutting edge, yet it is not hard enough to cut the material.
Theoretically, coolant is not needed to cut hard materials with CBN cutters. Having said that, people machine hard materials that require the use of CBN, yet these materials often times are sintered materials that contain soft molecules, such as copper, aluminum or beryllium that end up sticking to the cutting tool and forming the so called „built-up” edge that leads to the destruction of the cutting edges of that tool.
Consequently, coolant is more than necessary to machine alloys with carbide tools that are softer than 40 HRC. It is also recommended for CBN if one is not certain of the alloy that one machines. It turns out to be 90% of the cases.
Coolant must be abundant and must cover the cutting tool throughout the machining operation, without any interruption whatsoever, in order to avoid thermal shocks that literally cause cutting edges to explode!
Coolant shall soon become MANDATORY because of the use of new HARD/SOFT valve seat materials, composite sintered materials whose cut shall only be controlled under an uninterrupted flow of coolant fluid.
FIXED-TURNING® FOR THE HIGHEST QUALITY
numerically controlled axes driven by satellite roller screwsand servo-motors of the latest generation. A precision of the tool travelling by interpolation is measured in thousandths of mm.
Z-axis ( 250 mm / 9.84’’) mounted on linear ways authorizing any cylinder head position while guarantying systematic balancing of the spindle. Increased work capacity and increased machining precision. A NEWEN® exclusive.
NEWEN FIXED-TURNING® machining head featuring patented friction-free, pinion-free and maintenance-free kinematics, capable of machining with the highest degree of precision, year after year. Pilot centered and held by an original and particularly efficient crush sleeve system.
PRECISION IN EVERY COMPONENT AND DETAIL
The spindle is built into in the machine head moving on the x,y axis owing to an air cushion. Automatic centering with programmable temporization. Automatic re-centering of the spindle with pneumatic
Machining spindle mounted on special high precision bearing, greased for life. Powerful transmission via machined high precision spiral-beval pinion set.
Machine parallels mounted on linear ways, greased for life, entirely protected. Simple, fast and efficient mechanical lock to ensure effortless positioning of any cylinder head.
Electronic and electric components interconnected with quick plugs. Electronics entirely protected with stand alone suspended shock-proof cabinet. Electronics conceived and produced by NEWEN ®.
Solid honeycomb-design machine upper ways confers stability, longevity and precision to the machine.
SGC200M , palletizable™, 360° double-angle manual rollover clamping fixture. Allows quick positioning of most cylinder heads regardless of the valve guide angles. Also allows to simply raise cylinder heads to any desired level and to roll them over for various jobs. This patented system is quick, universal, very rigid, user friendly and does not put any stress on cylinder heads owing to its independant jaws and spherical collet clamping system.
Built-in low-voltage multipoint lightning (LEDs) - cold light. The work area is paricularly well lit, the control of the finished work is improved and, consequently, the operator’s fatigue is reduced.
15’’ Fanless Industrial PC of the latest generation, IP65, with built-in flat touch-screen. A user-friendly and intuitive dialogue between the machine and the operator. Unlimited memory capacity.
Control panel fitted with push-buttons, protected by an interchangeable lexan, and a multifunctional electronic wheel. Precision. Reliability
Stress relieved welded frame coated with industrial resin, resistant to any chemical agent (High frequency stabilization during welding).
NEWEN® CONTOUR-BB-CS™ : 2-Axis Single Point CNC Valve Seat & Guide Machine.
NEWEN FIXED-TURNING® MACHINING PROCESS (PATENTED)
X-Axis, machine head travel,
longitudinal head travel (distance from guide 760mm (29.92”)
to guide - X)
Y-Axis, machine head travel 60mm (2.36”)
Y’-Axis, machine parallels travel, 200mm (7.87”)
mounted on linear ways
Z-Axis, machine head travel (vertical travel), 250mm (9.84”)
mounted on linear ways
Z’-Axis, spindle sheath travel (for 80mm (3.15”)
machining purposes only)
X-Axis, carriage travel, automatic carriage 11mm (.43”)
displacement radius 22 mm in diameter
(ex : if tool set with a diameter of 20 mm, max machining dia
without repositoning p holder 42mm) Machining capacity 13.5mm - 100+mm
(.53” - 3.94+”)
Valve guide reaming capacity 65mm (2.56”)
Possible Profiles unlimited
Material to be machined Any material, from aluminum to tempered steels
Spindle rotation speed 300-2500 Rpm
Spindle motor 1.5 HP
Spindle, Feed and Carriage motors Servo Motors
Hydraulic unit 200 Bars (2,900psi)
PC 15 ‘‘Industrial type with
Connections RS232 – Ethernet
Centronics – USB
Operating System Windows 10
Electronic suspended cabinet with interchangeable fi lter
Built-in low-voltage multipoint lighting (LEDs)
Electronic depth gauge LVDT
Numerical control NEWEN®
CYLINDER HEAD DIMENSIONS
Maximum height (w/o removing pilot) 315mm (12.40”)
Maximum length unlimited
Maximum width Approx. 450mm (17.72”)
Maximum machine height 2205mm (86.81”)
Maximum machine width 1460mm (57.48”)
Maximum machine depth 1327mm (52.24”)
Machine net weight 800 Kg (1764 Lbs)
Machine gross weight 980 Kg (2160 Lbs)
Voltage 220V Single Phase,
Air Pressure Mini 6 bars, 90 Psi
Height 2090 mm
Depth 1380 mm
Length 1390 mm
Machining the most difficult cylinder heads is achieved within mere minutes per valve seat for the longest profiles, specially made to enhance the output of the engine. The machining of a traditional “3-Angle” profile will be carried out within a few seconds.
Motorcycle cylinder heads, the smallest valve seats around and to come (downsizing, at the heart of all the new engine development programs) can be machined with utmost ease and the optimum precision of competion engines...
NEWEN® machines allow each engine rebuilder to position himself as a specialist in the machining of all engine types. The precision that is achieved systematically when using FIXED-TURNING® machines applies to all the engine types, one no longer has to refuse getting involved in such or such machining on such or such cylinder head type, all the difficult machining operations become a source of additional and significant profits.
The high performance market, the mechanical leisure market, are within the reach of any engine rebuilder equipped with a FIXED-TURNING® machine.
All the precisions required in Formula 1 or any other demanding high performance mechanical sports can be attained automatically and systematically. Perfection is guaranteed.
High-Performance is a growing and lucrative market. The prestige of the high-level professional who gets involved in this specialty shines on his/her entire company.
The COGENERATION, also known as “Combined Heat and Power (CHP)”, the transformation of engines to natural gas and bio-fuels (ethanol) requires rapid and precise machining operations of valve seat counter-bores and very hard valve seats.
The principles of cogeneration have long been known and put to use in a wide variety of applications. Today, advances in ultra-clean natural gas fi red reciprocating engine technology, heat exchangers and system controls, make cogeneration both practical and economical for applications in varying size range.
One aspect of power production that has influenced these advances is the ever increasing need for cleaner energy. Emissions control strategies that allow natural gas fueled internal combustion engines to be applied for CHP & ICHM applications at levels equal to or less than current large power plant standards, have further made Cogeneration more practical, economic and accessible for a broader range of commerical and industrial applications.
FIXED-TURNING® is the ideal tool for these services which become easy, fast, precise and very profitable.
FIXED-TURNING® and its numerical control,
it is the possibility to achieve the impossible in a profitable
and repetitive fashiong. A technology for all.
To machine all the cam-bucket bore housings to oversize dimension in order to insert oversized sleeves in the housings is a simpe operation, precise and profitable with FIXED-TURNING®.
Create OFFSET profiles at will...
Machining of venturis (up to 112 degrees) to accelerate the speed of gases.
Venturi: An open angle below the seat that allows to accelerate the speed of exhaust gases through decompression.
Machine all high precision valve seat counterbores with one same cutting tool. To prepare valve seat housings in all types of cylinder heads, cast iron or aluminum, a precise and profitable job for all the FIXED-TURNING® professionals.
KOMATSU Natural Gas Cylinder Head
Valve Seat Hardness: 56/58HRC
(573HB+ / 610HV50+)
- Insert used: FT-11-11
- Cutting Speed: 180 m/min
- Machining Mode: Dry Cut
- Cutting Cycle: 28 sec/seat
- Circularity : 1μ to 2.40μ
- Surface Finish: 0.20Ra
Another NEWEN exclusive: the machining of Spark Plug Housing.
Machine with precision all types of valve guides (cast irons, powdered metals, bronze, any alloys...). Ream valve guides with utmost precision in a stand alone operation or in a combined valve seat machining operation.
To machine the seats of Mercedes Actros decompressor valves, “it’s child’s play”.
Opt for FIXED-TURNING® Perfection,
a technology for all and gain access to endless business opportunities...
Your assurance of success!
Automatic Repetive Depth Control (ARDC)
All NEWEN FIXED-TURNING® machines, including the CONTOUR-BB™, CONTOUR-BB-CS™, CONTOUR™, CONTOUR-CS™, EPOC-VISION™, are equipped with an electronic system to repeat the depth of cut with preci-sion. This system, developed by NEWEN, is not a measuring system per se but has been conceived to allow to repeat a machining position with precision, while taking a random reference on the cylinder head to machine. Generally, the reference for the NEWEN system is the cylinder head gasket plan, which is also used as a reference to measure valve seat depth. It is also possible, using a specific tooling, to use other surfaces, such as camshaft housings.
An electronic linear gauge, LVDT, (I) is connected to the numerical control of the machine. Depending upon the collapsed epth of the tip of the LVDT, the gauge sends an electric signal which allows to identify, with less than one hundredth of a mm, the position of the gauge.
This position can be memorized. Once the position memorized, the spindle feed motor is automatically stopped when the gauge is once again compressed the same amount. As a result, the equipment can machine all the valve seats at the same depth with respect to a chosen reference point.
• The gauge (I) has a fi xed position with respect to the axis of the pilot and with respect to the spindle sheath to which it is attached. This fi xed position remains when the spindle moves on its air cushion (C) and/or on its spherical air cushion (A).
• Drawing 3: All the seats are machined according to the same reference point (W), belonging to the reference plan and distant of a fixed measure (X), which is the same as the measure (X) in Drawing 1.
• The dimension (Z) on Drawing 2, is the amount of the gauge that is compressed and corresponds to a machining distant of the value (Y) on
Drawing 2 in comparison to the point of reference. This value (Y) can be modifi ed of a given and precise value using the controlled means of the numerical control (elevator, selection of repair dimensions...) which will modify the position of the tip of the gauge, and this latter will once more be memorized to be repeated as many times as desired.
• The collapsed amount (Z) of the gauge is not identical to the travel value of the spindle essentially because of the existing angle between the machine spindle and the gauge. Also, the LVDT is not a measuring instrument but a position indicator.
The NEWEN system for Automatic Repetitive Depth Control™, guarantees identical depth machining with variations not exceeding +/- one hundredth of a mm.
It is the only system available in the industry to guaranty an automatic machining of such precision, no matter the position of the cylinder head with respect to the cylinder head holding fi xture, with respect to the angle of the valve guides and with respect to the travel of the head of the machine.