18/11/2009
ABS Production from Sweden swears by inserts from CERATIZIT
Cutting tool specialist CERATIZIT gives a doubly convincing performance with CTC5235 |
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ABS Production AB in Vadstena, Sweden, produces XXL pumps for industrial applications and swears by machining solutions from CERATIZIT. Grade CTC5235 has been the runaway success for more than a year now.
The materials mainly machined by ABS Production are stainless steel (40%) and cast iron (50%), the remaining 10% is aluminium, titanium and bronze. For the production of a large pump the employees at ABS Production need an average of 115 hours. Out of these, 90 hours are required for machining, the remaining hours being spent on mounting and tests.
CERATIZIT grade CTC5235 achieved a 25 % time reduction
Milling the contact faces of the pump cases is one of the most important and simultaneously most difficult machining operations. This is where Hans Axelsson (CERATIZIT sales manager for North Europe) and Anders Laago (CERATIZIT key account manager for Sweden) had grade CTC5235 come in. Laago: “We analyzed the combination of material, parameters and results very carefully and were certain that we would be able to support ABS Production in all essentials.“ Tommy Johansson from ABS Production adds: “Mr Axelsson and Mr Laago were right. At the beginning the 25% time reduction already appeared substantial to me. But the CERATIZIT grade really provided surprising results: CTC5235 not only enabled a time reduction of 25% but also more than doubled tool life.“
The second time the CERATIZIT cutting tool specialists scored when machining so called ‘impellers’ which represent the core piece of the pumps. The outer edges of the impeller blades are finish-turned. Laago: “The challenge lies in the interrupted cut. It is not an even surface but single blades that are machined, the insert cutting each blade only very briefly: this means that the insert is exposed to impact and thermal stress. In fact these turning operations can basically be equated with a milling process. In the case of vibration or oscillations occurring during machining, the insert may break.”SPAN>
The machining operation required frequent tool changes. In the past six months CERATIZIT has been able to be of assistance again with grade CTC5235. The new inserts on average have a 100% longer service life in case of a 50% increase in cutting data. The requisites with regard to quality were fulfilled providing a burr-free surface.
We know how water works
The ABS group is the market leader in the field of pumps and periphery for pumping and circulation in the process industry, dewatering, wastewater network pumping stations and wastewater treatment. It is the ambitious goal to keep as much water as is possible clean, for ABS considers clean water the ‘gold of the future’. With their products and services in the field of wastewater transport and treatment the company contributes in an active and sustainable way.
The 170 ABS employees in Vadstena are knowledgeable about water and its optimal transportation. Pumps of the ABS brand are virtually all custom-made solutions: 75% of the orders require development work, the entire programme including only two standard pumps. Every year ABS Production manufactures around 5,000 pumps, 90% of which are delivered to customers abroad. The majority of pumps produced in Vadstena is applied in the paper industry, in water treatment and for fire-fighters. In addition to pumps, around 800 agitators and mixers are produced at the Vadstena plant every year, which are mainly applied to mix and circulate highly viscous liquids and paper pulp.
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Interview with Anders Petersson, production manager at ABS Production AB
What is the average price of a pump?
Petersson: "An ABS pump costs between 1,500 and 150,000 euros. 70% of this amount is made up of material costs. On average the pumps have a service life of 30 years or more."
What is the pump with the maximum performance you have produced up to now?
Petersson: "The pump with the highest performance in our range achieves three cubic metres per second and transports the water up to a height of 130 metres at a pressure of 13 bar. An engine power of 5,000 kW is necessary to operate the pump."
What are the trends in this market?
Petersson: "The pumps that are ordered are increasing in size, this is a very strong trend. We see new markets for bioethanol, wind energy and also oil industry, where we witness increasing investments in fire-extinguishing systems."
Since when have you been working together with CERATIZIT and how do you assess this business relationship?
Petersson: "We have been working together since the beginning of the 1990’s and would describe the cooperation as very good. CERATIZIT is a reliable partner concerning delivery time, product quality and technical support. With grade CTC5235 the company proves that they are now the technological leader."
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