Equipment

Powerful intellectual and manufacturing-technical potential of the plant allows creating the high class unique equipment. A number of manufactures equipped with all necessary equipment is a part of the plant.

Mechanical assembly manufacturing

About 1200 items of metal-cutting equipment including specialized and unit-built machines, automatic and semiautomatic machines, CNC machines and machining centers, unique machines are used in machine-assembly workshops:

  • turning-and-boring machine of K 19M model with processing diameter up to 25 000 mm;

  • a number of turning-and-boring machines with processing diameter of 1200-13000 mm including turning-and-boring machine with CNC SKJ 80-160D with processing diameter up to 16000 mm and with set of heads (for grinding and milling, boring);

  • horizontal boring machines with maximum processing zone of 15000×5000×3000 mm (LхHхW) including renewed machines “Skoda” (with possibility of 5-axis processing), “Pama” and Novosibirsk production association “Tyazhstankogidropress”;

  • milling-and-boring machine SPIRIT with spindle extension of 2950 mm which is unique for this type of equipment. The machine is equipped with three replaceable heads including 5-axis one as well as noncontact measuring systems and tool storage magazine. It is equipped with hydrostatic guideways in all coordinates of moving, it maintains the equipment accuracy characteristics for a long time;

  • high-speed milling-and-boring machines of Agile МЗ and Месmill models produced by “Emco-Mecof” with multi-axis (3+2) angle heads;

  • 10 machining center units manufactured by OJSC “IZTS”;

  • equipment for deep boring with processing length up to 6000 mm and bore diameter up to 1100 mm;

Permanent maintenance of technical and technological developments high level in accordance with world standards becomes possible owing to active cooperation with research-and-development establishments and higher education establishments of the country as well as with specialists of foreign firms.

  • horizontal-honing machine NTN 8000 with processing diameter from 40 to 560 mm and honing length up to 8000 mm;

  • thread-cutting machines of KZh-30 and 1682A models with processing diameters of 5000 and 4150 mm, with center-to-center distance of 16500 and 14000 mm correspondingly;

  • more than 10 items of new lathe machines with CNC manufactured by LLC “Ryazan machine tool plant” with processing diameter up to 1800 mm and center-to-center distance up to 10000 mm;

  • universal milling-and-turning processing 5-axis center DMС 80 performing milling and turning processing, with possibility of workpieces processing with diameter up to 800 mm and adjustment operations at adjustment site. Continuous cycle of processing is performed by means of 2 pallet tables. It is possible to perform surfaces form milling in 5-coordinate system;

  • universal milling-and-turning processing 5-axis center DMU210FD performing milling and turning processing, with possibility of workpieces processing with diameter up to 2000 mm, height up to 1250 mm and maximum weight of 5000 kg. The machine performs any module gear teeth milling, rotational frequency up to 12000 rpm provides high quality of surface;

  • high-accuracy turning-and-milling machine with CNC with high stiffness NL3000Y/2000 allows turning and milling processing of parts with diameter up to 430 mm and length up to 2000 mm, teeth cutting by hob cutter;

  • turning-and-milling processing center NT6600/4000CG with CNC is designed for turning and milling processing of parts with diameter up to 1070 mm and length up to 4076 mm, with possibility of inside diameters boring at the length up to 1500 mm and milling with speed up to 8000 rpm;

  • rigid-bed milling processing center of 66K45F4 model with working area overall dimensions 4500×12000×4000 mm (WхLхH);

  • two heavy portal machines TOS KURIM FRUNQ300В-VR/10 and FRUFQ 450B-VR/14 with tables 8000×3000 and 12000×4500 correspondingly allow processing the most complicated large parts with minimum number of setups. The machines are equipped with noncontact measuring systems of tool and part under processing, tool storage magazine and are able to perform 5-axis processing by means of special replaceable heads;

  • gear-milling machines for processing gear wheels with diameter up to 12400 mm and weight up to 180 tons by running method, including KU-306 models (Kolomna), machines produced by “Liebherr” and “Klingenberg” of L3002 and AMK-852 models correspondingly. These machines allow processing hardened beveled gears of cyclopalloid toothing with diameter up to 1100 mm and cut module up to m-21.5;

  • mobile instrumentation complex “FARO” allows obtaining the products geometrical parameters with accuracy from 0.02 mm in sphere with radius up to 35000 mm.

Welding production

The updated (“Kometa” model) and new (“Falcon” and “SUPRAREX” models produced by “ESAB”, the last is equipped with three-cutter swiveling block for edge cutting) thermal cutting machines with CNC are used in procuring and assembly-welding production.

During manufacturing, JSC “TYAZHMASH” actively applies advanced technologies of gas-flame spraying and plasma spraying, orbital welding.

For sheet material cutting the laser cutting machines ByStar 3015; ByStar L4025 8.0 produced by “ByStronic” are used.

Maximum width of an expanded sidewall in conditions of JSC “TYAZHMASH” manufacture may reach 8000 mm at maximum thickness of 30 mm.

Undeniable advantages:

  • hydraulic presses with the stress from 800 tons-force to 2500 tons-force;

  • sheet bending and forming machines including “HAUSLER” unique rolls allowing to process sheet material with width up to 4000 mm and thickness up to 240 mm (hot method);

  • units for electro-slag welding of ring and line welds with thickness up to 350 mm.

Implementation of FACCIN Synchro 4HEL machines three modifications to perform the expansion of parts with big, medium, and small thickness allowed to process workpieces with thickness from 8 to 100 mm. Due to high speed and accuracy of expansion, time of processing significantly decreased and workpieces quality increased.

Картинка Описание

Implementation of FACCIN Synchro 4HEL machines three modifications to perform the expansion of parts with big, medium, and small thickness allowed to process workpieces with thickness from 8 to 100 mm. Due to high speed and accuracy of expansion, time of processing significantly decreased and workpieces quality increased.

Implementation of FACCIN Synchro 4HEL machines three modifications to perform the expansion of parts with big, medium, and small thickness allowed to process workpieces with thickness from 8 to 100 mm. Due to high speed and accuracy of expansion, time of processing significantly decreased and workpieces quality increased.

Milling machine FRUFQ 450B-VR/14 was put into operation in 2012 in the workshop No. 5, FRUNQ 300B-VR/10 — in the workshop No. 30. Differential characteristics are as follows: high-speed processing the most complicated large parts, processing the most complicated parts with minimum number of setups. The machines are equipped with three replaceable heads. The first head is five-axis. The second head is designed for 300 mm (extension), the third is double-axis angle head designed for parts processing in horizontal plane. The important advantage of this equipment is a laser system of tool measurement and possibility to change machined surfaces. It eliminates errors connected with human factor impact.

Milling machine FRUFQ 450B-VR/14 was put into operation in 2012 in the workshop No. 5, FRUNQ 300B-VR/10 — in the workshop No. 30. Differential characteristics are as follows: high-speed processing the most complicated large parts, processing the most complicated parts with minimum number of setups. The machines are equipped with three replaceable heads. The first head is five-axis. The second head is designed for 300 mm (extension), the third is double-axis angle head designed for parts processing in horizontal plane. The important advantage of this equipment is a laser system of tool measurement and possibility to change machined surfaces. It eliminates errors connected with human factor impact.

In September 2012 the new machine SPIRIT produced by Italian company „FPT” was put into operation in the workshop No. 30. High speed is the main advantage of this machine. Besides, the machine is equipped with special accessories expanding its processing capabilities including main five-axis milling head and head positioning according to principle 3+2. Thee new machine is equipped with slide „D’Andrea” (allowing to bore holes with diameter up to 1600 mm), rotary table with lifting capacity of 70 t and dimensions of 3000×3000 mm. All these facts along with high power (103 kW) allow processing the parts of any sharp in short time. These characteristics make the equipment unique and indispensable.

Painting-and-drying chambers Venus 1287 were put into operation in 2012 in workshops Nos. 17 and 30. Characteristics are as follows: automatic control of painting and drying temperature (Т max = 80 °С), effective ventilation system (air capacity is 70000 m3/h). Combination of pressure and exhaust ventilation prevents painting particles from gathering in chamber. Temperature increase allows to reduce drying period two times as compared with drying „in the open air”. Chamber advantage is a possibility to apply not only standard spray units, in which paint is mixed with air, but also airless spraying devices.

In March 2011 shot-blasting chamber Blastlux PC-BL 1287 was installed in the workshop No. 7. The installed chamber is designed for shot blasting (before painting) of various products with weight up to 100 tons. Main advantages of the chamber are as follows: high efficiency, noiseless operation, low power consumption, well illumination realized in side and ceiling arrangement of lamps. Effective system of ventilation provides clear visibility, instant removal of pulverized coal. It ensures well quality of surface treatment. Programmable control system operates the work of all units and provides processes automation. Two automatic platforms are installed inside. Operators may move on them during shot blasting, it makes their work easier.

Steel rods and blocks sawing into blank parts is performed on bandsawing machines installed in the workshops Nos. 3 and 16. One of the indisputable advantages of new equipment is a high rate and quality of cutting. Edges of blank parts are flat, without burrs, and their further processing is not labour-intensive. Operating speed with rolled products of small diameter may be increased by means of piled-plate cutting, when several steel rods are cut simultaneously. The largest bandsawing machine of H-5550 model (workshop No. 3) may cut forgings with diameter up to 500 mm. Models with less power such as H-360HANC and H-260HB work with diameters up to 360 mm (workshop No. 16) and 260 mm (workshop No. № 3). Another advantage of equipment is shallow thickness of sawcut. It allows material saving and wastes minimization.

Press Xpert was put into operation in April 2011 in the workshop No. 17. Its capabilities allow to perform sheet bending works with blank parts with thickness from 0.5 to 40 mm and all necessary radii. Owing to built-in automation equipment (such as CNC and device for lateral and upper support), the equipment provides possibility to simplify the work of operator and to increase efficiency.