CONTOUR-BB-CS™
A technology concentrate !
NEWEN® CONTOUR-BB-CS™ : 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 ?
VALVE GUIDES
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.
VALVE SEATS
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.
The benefit:
A faster production, more precise and with a lower cost, and a first rate quality job.
COOLANT
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.
HIGHLIGHTS
Like the principle of a CNC lathe, FIXED-TURNING ® is the machining of valve seats and/or any revolution shape by interpolation of axes.
Aside from the fact that it is the cutting tool that is spinning and not the part being machined itself, the machine spindle and machining head allow to very simply machine the most difficult and most complex shapes regardless of the quality of the valve seat material. While rotating, the cutting tool moves on its x and z axes to describe the profile to machine. The machining is performed in one direction and the number of passes is automatically defined by the program itself. The travel of the cutting tool is optimized according to the actual shape of the raw valve seat. A standard triangular cutter moves according to the axis of the carriage and the axis of displacement of the spindle. The whole rotates around the C-axis.
A powerful computer permanently calculates the optimal trajectory of the tool so that the cutting efforts are regular and reduced to a minimum. Every single shaving calculated from a fraction of a second to a fraction of a second is produced in such way that no fluctuation of the cutting efforts disrupts the balance and the flexibility of the spindle.
Thanks to FIXED-TURNING ®, perfect valve seat machining and a perfect seal between the valve seat and its valve are attained each and every time, the first time, without lapping.
Modern controls, latest technology, efficient, simple, extremely user friendly, relieves the operator of repetitive gestures, reduces fatigue and frees up attention for essential operations.
The interaction with the machine is user friendly and simple. The operator only needs to enter familiar dimensions such as the diameter of the valve, select a profile and the machine will instantaneously calculate everything else, including all roughing and finishing machining passes.
Beyond precision, beyond mere user friendliness and added productivity, FIXED-TURNING® is the equivalent of thousands of custom form tools, all permanently packaged in one simple and affordable machine.
Long Live Engine Rebuilding.
TECHNICAL CHARACTERISTICS
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
touch screen
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®
Software NEWEN®
CYLINDER HEAD DIMENSIONS
Maximum height (w/o removing pilot) 315mm (12.40”)
Maximum length unlimited
Maximum width Approx. 450mm (17.72”)
MACHINE DIMENSIONS
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,
50-60 Hz
Air Pressure Mini 6 bars, 90 Psi
PACKING DIMENSIONS
Height 2090 mm
Depth 1380 mm
Length 1390 mm
FIXED-TURNING® CAPABILITIES
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.
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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.
Opt for FIXED-TURNING® Perfection,
a technology for all and gain access to endless business opportunities...
Your assurance of success!
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.
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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”.
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.