Russian Precision Metal-Cutting Machines

SREDNEVOLGSKY STANKOZAVOD LTD.

FEDERAL STATE UNITARY ENTERPRISE FEDERAL RESEARCH AND PRODUCTION CENTER «PA «START» named after M.V.PROTSENKO»

HIGH-QUALITY SOLUTIONS IN THE FIELD OF METAL- WORKING

RUSSIAN PRECISION METAL-CUTTING MACHINES

www.svsz.ru www.startatom.ru SREDNEVOLGSKY STANKOZAVOD LTD.

TECHNOLOGICAL CAPABILITIES OF SREDNEVOLGSKY STANKOZAVOD LTD.

The Srednevolgsky stankozavod Ltd. was established in 1876. It is one of the oldest machine building enterprises, not only in Russia, but also in the world. During more than 100 years the plant has produced more than half a million of lathes. Legendary models of machines 1А616 and 16B16 are still respected by turner for its high reliability, easy operation and high processing accuracy. The plant was the first in the USSR to master the production of CNC machines. Srednevolgsky stankozavod Ltd. has all the technological competencies for production of high precision lathes. The Machine Plant range of products includes more than 200 units of technological equipment which enables high-precision machining of large pieces of casting, gear processing, ultra-precise finishing operations of surface grinding of spindles, shafts, gears, precision boring operations. All mechanical components of machines, including base frame, spindle assembly, stand, tailstock are made directly at the facilities of Srednevolgsky stankozavod Ltd. To ensure the required accuracy and its long-term operation, all basic parts of machines are subjected to various stabilization of geometrical sizes (natural and artificial ag- ing), bed guides of high quality cast iron are heat treated at high frequency current installations. Critical parts of machines (spindles, quill, lead screws, gears, etc., are made of alloy steels which are subjected to various heat treatment methods, including ionic and gas nitriding, nitrogen and ionic carbonization, etc. When manufacturing critical and basic parts, the follow- ing is widely used: ultra-precise grinding, gear-grinding and thread-grinding machines and other advanced equipment. The plant metrological service using advanced inspection instruments, for example, laser interferometers, profilers, different types of microscopes, hardness measuring instruments, etc. contributes to stable product quality. The basic principle during assembly and installation of the products is subassembly and bench assembly with wide running-in of assembled units. To reduce noise and vibration, the main motion drive components and individual parts are dynamically balanced. Finished machines are tested for reliability, rigidity and running under power (cut- ting1). At present, the plant is completely focused on the production of machines with precision accuracy classes А, В and П according to GOST 8-82. The plant is the only Russian manufacturer of ultraprecision lathes.

2 HIGH-QUALITY SOLUTIONS IN THE FIELD OF METALWORKING FEDERAL STATE UNITARY ENTERPRISE FEDERAL RESEARCH AND PRO- DUCTION CENTER «PA «START» named after M.V.PROTSENKO» TECHNOLOGICAL CAPABILITIES OF PRODUCTION ASSOCIATION “START”

Production Association “Start” is the largest enterprise in the Penza Oblast, one of the leading and dynamically developing instrument-making enterprises of the State Cor- poration “Rosatom”. The enterprise manufactured its first product on June 30, 1958 and since then it has been con- stantly developing, increasing production capacity and im- proving the used technology. Manufacture of machines at PA “Start” has a long histo- ry. In 1993, the company has produced the first batch of mills. Over the next ten years production of nine types of small lathes, mills and woodworking machines, including mills with program control, has been established. Several hundred pieces of equipment have been exported to the countries of Western Europe. To date, the company assembles lathe with operational control system Samat 400 “VECTOR” and its modifications. In addition to the assembly of components supplied by Srednevolgsky stankozavod Ltd., the enterprise special- ists perform final machining, manual scouring of parts re- sponsible for ensuring kinematic accuracy, adjustment and monitoring of a finished machine. During scouring of stand, carriage, seats of drives, headstock and tail stock, the surface-to-surface accuracy of the machine parts is not more than 3 µm to ensure the workpiece noncylindricity of not more than 5 µm. About 20 special precision devices and instruments are used for machine control during assembly. To ensure the absolute quality of the produced machines, Srednevolzhskiy Machine Plant and Production Associa- tion “Start” have decided to almost completely localize the component production at their own facilities. Strate- gic partnership of Federal State Unitary Enterprise Federal Research and Production Center «PA «START» named after M.V.Protsenko» and Srednevolgsky stankozavod Ltd. is a new stage of development of Srednevolgsky stankozavod Ltd.. Joint production of new products, lathe with operational control, has been set. New ultraprecision machines are being designed. New systems for mechanical working of parts and assembly of machines are being commissioned. The Partnership plans to enter foreign markets in Europe, Africa, America

3 SREDNEVOLGSKY STANKOZAVOD LTD. MULTIPURPOSE MACHINES MULTIPURPOSE Lathes MACHINES WITH PROGRAM CONTROL Multipurpose machines with CNC lathes operational program control SPECIAL MACHINES

Special machines Turning and backing machines

4 HIGH-QUALITY SOLUTIONS IN THE FIELD OF METALWORKING FEDERAL STATE UNITARY ENTERPRISE FEDERAL RESEARCH AND PRO- DUCTION CENTER «PA «START» named after M.V.PROTSENKO» SERIES OF MULTIPURPOSE LATHES WITH OPERATIONAL PROGRAM CONTROL SAMAT 400 «VECTOR»

RUSSIAN PRECISION METAL-CUTTING MACHINES

FUNCTIONS OF OPERATIONAL CONTROL SYSTEM

Ergonomic stand-alone remote control panel Number of controls is significantly reduced. Controls are in the visibility zone of the part processing.

Machine “Vector” has a wide range of standard programs (microcycles), excluding the monotone operations.

Thread Sphere Cone Draft picks

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MULTIPURPOSE LATHE WITH OPERATIONAL PROGRAM CONTROL “VECTOR”

Series of multipurpose lathes with miniprogram (operational) control includes models Samat 400 ХС, SC, MC with a maximum turning diameter over bed of 400 mm and center to center distance of 500, 750 and 1000 mm. The machines are equipped with original control system on the basis of program controller and motion drives along X and Z axes by Japanese company OMRON. They are available in two versions: accuracy class П (increased) and accuracy class B (high) according to GOST 8-82. During the machine delivery, commissioning and operator training are performed. The machines are designed for a variety of turning operations for sole, small batch and mass production. Retaining all the advantages of a multipurpose machine, the machine allows automatic operation: the program can be saved during processing of the first details by the operator, or it can be entered using a wide range of micro cycles. When equipped with 4- or 8-position heads, the machine can be used for large scale and mass production.

EQUIPMENT:

- operative control system based on the programmable controller; - tool holder Multifix, with replaceable cartridges (4 pcs.); - automatic 4-position tool head; - self-centering scroll chucks with 3 and 4 cams; - rack to cartridge; - collet sleeve; - reducing bushing; - collets (outer diameter clip); - collets (inner diameter clip); - drill chuck; - reducing bushings for holding tools with taper shank Morse GOST 18598 -85; - dead center Morse 5, 6; - running center Morse 5; - fixed rest; - rubber anti-vibration supports; - set of tools and spare parts for machine maintenance; - packaging; - commissioning and operator training.

6 HIGH-QUALITY SOLUTIONS IN THE FIELD OF METALWORKING FEDERAL STATE UNITARY ENTERPRISE FEDERAL RESEARCH AND PRO- DUCTION CENTER «PA «START» named after M.V.PROTSENKO» SERIES OF MULTIPURPOSE LATHES WITH OPERATIONAL PROGRAM CONTROL SAMAT 400 «VECTOR»

Tolerance, µm, for accuracy classes Parameter П В Out-of-roundness, max 7 2.5 End straightness, max 10 6 Spindle radial runout, max 7 5

ADVANTAGES

- high performance - ability to process automatically; - easy operation - fast training of operators; - intuitive interface; - wide range of micro cycles - longitudinal turning, boring holes, all kinds of cutting, cone, sphere, etc.; - different tool equipping; - optimization of cutting conditions with a stepless spindle speed; - easy operation similar to conventional multipurpose lathe; - does not require special programming skills; - learning mode reduces time for program preparation

Model SAMAT 400 Technical characteristics ХС SC МС Machine accuracy class according to GOST 8-82 П / В Maximum diameter of workpiece installed above base frame, mm 400 Maximum diameter of workpiece installed above stand, mm 220 Maximum length of installed workpiece, mm: 500 750 1000 Diameter of hole in spindle, mm 45 Height of tool in tool holder, mm 25 Conical hole in spindle Morse 6 Conical hole of tailstock quill Morse 5 Number of spindle speeds Stepless Range of spindle speed, rpm 25-2500 Maximum spindle torque, Nm 135 Feed per revolution limits, mm/rev: - longitudinal 0,01-9,99 - transverse 0,005-4,99 Speed of rapid moves in automatic/manual mode, mm/min: - longitudinal 7000/6000 - transverse 3500/3000 Increment in manual mode, mm - longitudinal 0,01 - transverse 0,005 Limits of cut thread steps: - metric, mm ОД-56 - inch, number of threads per inch 23-1 Main motion motor power, KW 5,5 Machine overall dimensions, max, mm: length 1975 2225 2475 width 1190 1190 1190 height 1470 1470 1470 Machine weight, kg 2415 2550 2700

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AUTOMATIC SCREW MACHINES

SCREW-CUTTING LATHE of ULTRA HIGH PRECISION MODEL «SAMAT 400 S/S»; ACCURACY CLASS A ACCORDING TO GOST 8-82 - Out-of-roundness, max 1.6 µm - End straightness, max 4 µm - Surface roughness Ra 1,25 (for ferrous metals) Are used in small scale and mass production of industrial enterprises, at individual workshops.

Microgear reducer

Support mechanism Transverse feed screw with nonius division value of 0.02 mm

DEFAULT SET: - rear tool holder; - longitudinal travel fixed stop; - stop drum; - set of change gears; - digital display device; - set of tools for machine maintenance; - drill chuck; - commissioning work; - self-centering lathe chuck with 3 jaws, D 160 - 250 mm; - packaging - wooden pallet, polyethylene. - lathe chuck with 4 jaws D 250 mm; - running centers Morse 5; OPTIONS BY CUSTOMER REQUEST: - dead centers Morse 5 and 6; - tool holder Multifix with replaceable cartridges - extra set of change gears; (4 pcs.); - rigid jacks (set); - mobile and fixed rest; - packing: wooden box.

8 HIGH-QUALITY SOLUTIONS IN THE FIELD OF METALWORKING FEDERAL STATE UNITARY ENTERPRISE FEDERAL RESEARCH AND PRO- DUCTION CENTER «PA «START» named after M.V.PROTSENKO»

RUSSIAN PRECISION METAL-CUTTING MACHINES ADVANTAGES:

- finishing grinding is not necessary due to micron accuracy precision; - ability to perform a variety of turning operations, as well as cutting all kinds of threads; - stepless main drive (2800 rpm); - wide range of longitudinal and transverse feeds; - support rapid movement at idle; - ability to perform highly precise processes using the most advanced tools.

Specifications SAMАТ 400 SS Machine accuracy class according to GOST 8-82 A Maximum diameter of workpiece installed above base frame, mm 400 Maximum diameter of workpiece installed above stand, mm 220 Maximum length of installed workpiece, mm: 750 (500) * Diameter of hole in spindle, mm 45 Height of tool in tool holder, mm 25 Conical hole in spindle Morse 6 Conical hole of tailstock quill Morse 5 Number of spindle speeds Stepless Range of spindle speed, rpm 16-2800 Feed per revolution limits, mm/rev: - longitudinal 0,01-2,30 - transverse 0,005-1,400 Limits of cut thread steps: - metric, pitch in mm 0,253-56 - inch, number of threads per inch 112-0,5 - modular, step in modules 0,25-56 - pitch, step in pitches 112-0,5 Speed of rapid moves in automatic/manual mode, mm/min: - longitudinal 7000/6000 - transverse 3500/3000 Accuracy of geometric shape of sample surface, mm - constancy of diameter in cross section over length of 200 0,001 - constancy of diameter in longitudinal section 0,003 Surface roughness after finishing Ra 1.25 Straightness of end surface, mm 0.0025 Main motion motor power, kW 5.5 Machine overall dimensions, max, mm: length 2270 width 1110 height 1505 Machine weight, kg 2100 * Machine version with center to center distance of 500 mm is possible.

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AUTOMATIC SCREW MACHINES

Series of screw-cutting multipurpose lathes includes models Samat 400 XV, SV, MV, LV, analog of 16Б16, with maximum turning diameter above bed of 400 mm and center to center distance of 500, 750, 1000, and 1500 mm. Accuracy class П (increased) according to GOST 8-82.

DEFAULT SET: OPTIONS BY CUSTOMER REQUEST: - Longitudinal travel fixed stop; - Tool holder Multifix, with replaceable cartridges - Set of change gears; (4 pcs.) - Set of tools for machine maintenance; - Mobile and fixed rest; - Commissioning works; - Rear tool holder; - Packaging - wooden pallet, polyethylene. - Stop drum; - Digital display device; - Drill chuck; - Self-centering lathe chuck with 3 jaws, D 160 - 250 mm; - Lathe chuck with 4 jaws D 250mm; - Running centers Morse 5; - Dead centers Morse 5 and 6; - Extra set of change gears; - Rigid jacks (set); - Packaging: wooden box

10 HIGH-QUALITY SOLUTIONS IN THE FIELD OF METALWORKING FEDERAL STATE UNITARY ENTERPRISE FEDERAL RESEARCH AND PRO- DUCTION CENTER «PA «START» named after M.V.PROTSENKO»

RUSSIAN PRECISION METAL-CUTTING MACHINES ADVANTAGES:

- simple and reliable design providing long service life, ease of use and maintenance; - ability to perform a variety of turning operations, as well as cutting all kinds of threads; - main drives based on frequency converters ensuring stepless control of spindle speed; - wide range of longitudinal and transverse feeds; - support rapid movement at idle; Model SAMАТ 400 Specifications XV SV MV LV Machine accuracy class according to GOST 8-82 П Maximum diameter of workpiece installed above base frame, mm 400 Maximum diameter of workpiece installed above stand, mm 220 Maximum diameter of workpiece installed in stand gap (ГАП), mm 550 Maximum length of installed workpiece, mm: 500 750 1000 1500 Diameter of hole in spindle, mm 45 Height of tool in tool holder, mm 25 Conical hole in spindle Morse 6 Conical hole of tailstock quill Morse 5 Number of spindle speeds Stepless Range of spindle speed, rpm 12-2200 Feed per revolution limits, mm/rev: - longitudinal 0,05-2,80 - transverse 0,025-1,400 Limits of cut thread steps: - metric, pitch in mm 0,25-56 - inch, number of threads per inch 112-0,5 - modular, step in modules 0,25-56 - pitch, step in pitches 112-0,5 Accuracy of geometric shape of sample surface, mm - constancy of diameter in cross section over length of 200 0,007 - constancy of diameter in longitudinal section 0,012 Surface roughness after finishing Ra 2,5 Straightness of end surface, mm 0.01 Main motion motor power, KW 5,5/7,5 Machine overall dimensions, max, mm: length 2020 2270 2580 3000 width 1110 1110 1110 1050 height 1505 1505 1505 1450 Machine weight, kg 2040 2085 2130 2550

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CNC LATHE OF MODEL 16Б16Т1

CNC lathe mod. 16Б16Т1 is used in small, medium-scale and mass production for turning parts in semi- automatic cycle, as well as in automatic cycle when equipped with automatic means for loading and- un loading of workpieces.

DEFAULT SET: OPTIONS BY CUSTOMER REQUEST: - CNC unit (NC-201M); - 8-position tool head PRAGATi ВТР - 50; - 8-position tool head; - pneumatic drive with 3 jaw wedge-type chuck - set of tools and spare parts for machine mainte- with 200 mm diameter; nance; - 3 jaw chuck with built-in pneumatic cylinder - packaging - wooden pallet, polyethylene. SMW AUTOBLOCK; - self-centering lathe chuck with 3 jaws, D 200 mm; - running centers Morse 5 (extended); - fixed rest; - version of CNC drives and devices by SIEMENS; - rod feed device (rod diameter of 40 mm); - rubber anti-vibration supports; - commissioning and operator training.

12 HIGH-QUALITY SOLUTIONS IN THE FIELD OF METALWORKING FEDERAL STATE UNITARY ENTERPRISE FEDERAL RESEARCH AND PRO- DUCTION CENTER «PA «START» named after M.V.PROTSENKO»

RUSSIAN PRECISION METAL-CUTTING MACHINES ADVANTAGES:

- different turning operations, including processing of parts with a curved, stepped profile, cutting of- dif ferent threads in semi-automatic cycle; - 8-position tool head (possibility to install sufficient number of tools for complete machining of part or for group tool adjustment); - precision servo feeds; - CNC device programmed from operator’s workplace, as well as from external media; - pneumatic mechanical clamping of parts in spindle chuck; - electromechanical adjustable clamping of part by tailstock center; - enclosure of machine working area; - possibility of multi-machine service

Specifications 16Б16Т1 16Б16ТШ Machine accuracy class according to GOST 8-82 П Maximum diameter of workpiece installed above base frame, mm 400 Maximum diameter of workpiece installed above stand, mm 135 Type of CNC unit NC-201M (SIEMENS 808) Maximum length of installed workpiece, mm: 750 1000 Diameter of hole in spindle, mm 4S Height of tool in tool holder, mm (20} 2S Conical hole in spindle Morse 6 Conical hole of tailstock quill Morse 5 Range of spindle speed, rpm 25-2800 (3200) Maximum spindle torque, Nm 210 Feed per revolution limits, mm/rev: - longitudinal 0,01-20.47 - transverse 0,005-10.230 Speed of rapid moves, mm/min: - longitudinal 10000 - transverse 5000 Limits of cut thread cutting, mm 0,05-40,00 Increment, mm - longitudinal 0,001 - transverse 0,001 Main motion motor power, KW 7,5 Machine overall dimensions, max, mm: length 2650 2900 width 1370 1370 height 1740 1740 Machine weight, kg 2620 2770 * Machine version with center to center distance of 500 mm is possible.

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BACKING-OFF LATHES

Used in small batch and individual production for backing-off of worm-modular milling cutters (single thread and multiple thread, left and right), disc cutters and other tools with teeth, backed off radially, at an angle or along the axis with cutter or grinding wheel.

DEFAULT SET: OPTIONS BY CUSTOMER REQUEST: - set of change gears; - grinding head; - set of tools and spare parts for machine mainte- - wheel dressing device nance; - long faceplate; - accessory set [rod for fixing mandrels, dead cen- - rubber anti-vibration supports; ter, driving faceplate, semicenter, mandrels - 27 mm, 32 mm, 40 mm, safety device); - packing - wooden pallet, polyethylene.

14 HIGH-QUALITY SOLUTIONS IN THE FIELD OF METALWORKING FEDERAL STATE UNITARY ENTERPRISE FEDERAL RESEARCH AND PRO- DUCTION CENTER «PA «START» named after M.V.PROTSENKO»

RUSSIAN PRECISION METAL-CUTTING MACHINES ADVANTAGES:

- ability to manufacture worm milling cutters of class A; - combining of lathe machining of elements of cutter teeth and finishing grinding of machines milling cutters; - processing of shaped elements in cam mechanism of different purposes Model 1Е811 1Е812 Specifications Maximum diameter of workpiece installed above base frame, mm 250 360 Maximum distance between centers, mm 630 Maximum length of carriage travel, mm 600 Maximum tool height, mm 35 43 Dead center in spindle of headstock according to GOST 13214-79 Morse 6 Nominal size of spindle front end according to GOST 12595-72 6К Maximum backing-off travel, mm 20 25 Range of spindle speed, rpm 2-115/2-146 1-56/2-115 Number of backing-off travel values Stepless Teeth processing number limits 1 ... 40 Maximum spindle torque, Nm 2,1/1,68 3,1/2,5 Number of longitudinal feeds 3 Feed limits, mm/rev 0,075-1,2 Limits of cut thread steps: - metric, mm 0,5-250 0,5-360 - modular, mm 0,5-250 0,5-360 - inch, number of threads per inch 28-2 28-2 Limits of spiral grooves steps during backing-off, mm 100 ... 48000 Diameter of hole in spindle, mm 42 Maximum transverse support movement, mm 50 Support rotation angle, deg. ±180 Machine overall dimensions, max, mm: length 2900 2900 width 1750 1850 height 1900 1900 Machine weight (without electrical equipment), kg 3915 4285 Grinding head Maximum diameter of grinded workpiece, mm 180 250 Maximum diameter of grinding wheel, mm 125 150 Number of grinding spindle speeds, 3 Range of grinding spindle speed, rpm 5600... 11200 5000... 10000 Maximum angle of grinded lifting thread, deg. 25 Wheel dressing device Maximum length of dressing line, mm 40 Dividing faceplate Number of processed thread entries 2,3,4,5,6,10,12

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SPECIAL MACHINES

Srednevolgsky stankozavod Ltd. develops and manufactures special machines, semi-automatic lathes, automatic lines for solving individual problems of the customer.

Semi automatic lathe with the operational program management of CT-110 for the treatment of the rotors.

Machine with operational program management for machining of special materials. The machine has a sealed work area with an exhaust hood to remove dust.

16 HIGH-QUALITY SOLUTIONS IN THE FIELD OF METALWORKING FEDERAL STATE UNITARY ENTERPRISE FEDERAL RESEARCH AND PRO- DUCTION CENTER «PA «START» named after M.V.PROTSENKO» NOTES

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NOTES

18 HIGH-QUALITY SOLUTIONS IN THE FIELD OF METALWORKING FEDERAL STATE UNITARY ENTERPRISE FEDERAL RESEARCH AND PRO- DUCTION CENTER «PA «START» named after M.V.PROTSENKO» NOTES

19 SREDNEVOLGSKY STANKOZAVOD LTD.

FEDERAL STATE UNITARY ENTERPRISE FEDERAL RESEARCH AND PRODUCTION CENTER «PA «START» named after M.V.PROTSENKO»

www.svsz.ru SREDNEVOLGSKY www.startatom.ru STANKOZAVOD LTD. Naberezhnay reki Samary, 1, Samara, 443036 FEDERAL STATE UNITARY ENTERPRISE FEDERAL RESEARCH Office: AND PRODUCTION CENTER (846) 321 -00-23 (24) «PA «START» named after [email protected] M.V.PROTSENKO»

Sales department: Prospekt Mira, 1, Zarechniy, (846) 321-00-23 442960, Penza Oblast, [email protected] Tel.:(8412) 23-29-51, 60-17-94 fax: (8412) 65-17-34 Service center: E-mail: [email protected] (846)321-00-24 www.startatom.ru [email protected]