Oil and gas manufacturer transforms production with Ibarmia five-axis machining centre from Dugard

Cutting and Wear Resistant Developments Ltd, a manufacturer of specialist downhole tools for the oil and gas industry, has undergone a transformative shift in its production capabilities after investing in an Ibarmia five-axis travelling-column machining centre from Dugard. The company, led by Managing Director Matthew Cooper, has followed a successful growth trajectory over the past 12 years, and the introduction of this advanced CNC machine has played a pivotal role in supporting its expansion.

Cutting and Wear’s unique selling proposition lies in its ability to manufacture tools with a hard-facing aspect and integrate innovative machining processes to deliver comprehensive solutions for its customers. Prior to the arrival of the Ibarmia ZVH 45 L3000 machine, the company encountered challenges related to the complexity of its tools, lead time constraints and the efficiency of its manufacturing methods. However, the implementation of the new machine has revolutionised their operations.

“In my 12 years here I’ve seen many changes, both in the company and the industry pleasingly, we’ve adhered to a successful growth plan, leading us to where we are today—continuing that growth and progressing in the right direction with new machine investments,” explains Matthew Cooper.

The Ibarmia machine, equipped with a high-performance spindle capable of speeds up to 12,000 rpm, has enabled Cutting and Wear to reduce lead times and machining times significantly.

Mark Taylor, a CNC Programmer at Cutting and Wear Ltd, highlights an example: “We had one tool that previously took us 11 hours to mill; on the new machine, it was reduced to just two hours. That’s a massive improvement for us.”

One of the stand-out features of the Ibarmia machine is its advanced probing capabilities. By integrating probing into the machine’s programming cycle, Cutting and Wear has eliminated the need for manual programming, further streamlining the manufacturing process.

“We can execute everything on the machine as it’s built into program, so there’s no need to remove it from the machine for inspection, and that’s a time saver as well,” says Mark Taylor.

The Ibarmia ZVH 45 L3000 machine from Dugard is a five-axis travelling-column machine with an X, Y and Z axis travel of 3000 by 1200 by 800 mm, and a B-axis head range of +/-105 degrees. Supplied with an SK40 head as standard or HSK A-63 as an option, the ZVH 45 has a 45 kW spindle with 200 Nm of torque. Provided with a FANUC or Heidenhain TNC control, the ZVH 45 L3000 is available with a multitude of options to maximise productivity for the end user.

The machine’s state-of-the-art graphics function has also significantly enhanced the programming experience. Mark Taylor notes that approximately 90% of the programming is now done offline, with the remaining 10% proven on the machine.

“The graphics have been tremendously improved on these machines. A lot of the programming – I’d say 90% – is done through offline programming, and then we have to prove it out here. However, with the graphics function on this machine, it just makes everything so much easier and reduces errors.”

The simultaneous five-axis machining capabilities of the Ibarmia machine have been a game-changer for Cutting and Wear. This technology allows the machine to perform complex, multi-dimensional operations with a single set-up, significantly reducing the need for manual intervention and enhancing overall efficiency.

“It was a learning curve because it has a simultaneous head. We have quite similar machines, but this one is a lot quicker.”

The introduction of the Ibarmia machine has influenced the mindsets of Cutting and Wear’s machinists, as Matthew Cooper explains: “Not only has the machine changed our manufacturing methods, but it has also shifted the thinking of our operators. They’ve completely embraced the new technology, flipping their approach to the manufacture of down-hole tools. The Ibarmia machine’s advanced features – including its high-speed spindle, integrated probing and state-of-the-art graphics – have allowed us to achieve notable improvements in accuracy, speed and programming efficiency.”

In addition to its technical capabilities, the strong partnership between Cutting and Wear and Dugard has been instrumental in the success of this investment.

“Dugard came in, worked with us very closely, understood the tools we wanted to produce, and from then on simply matched us with the appropriate machines,” says Matthew Cooper. “So it’s a well-suited relationship and the machines are doing precisely as Dugard said they would.”