Heat exchangers – Tube Sheet
Heat exchanger has many tubes running through a sealed shell, and by covering the tubes with fluids that hold different thermal energies, the heat energy is exchanged between the fluid in the tubes and the fluid in the shell.
The main process for tube sheet is drilling due to the large number of holes. Improving the process efficiency of drilling is one of the keys to improving productivity.Tungaloy offers a wide range of tools and solutions to improve tube sheet production.
Tooling concepts
- High-efficient rough turning with the combination of “high D.O.C” and “high feed” method
- Deep drilling solution with high productivity and high accuracy
- Internal groove by milling that enables process integration
- Highly economical and high productivity chamfering solutions
Featured process
Process 1: Rough face turning
Benefits
- Apply high D.O.C turning for removing forged skins. By reducing the number of machining paths, the effects of work hardening of materials are reduced and the tool life is extended
- After the operation of removing forged skin, apply high feed turning to reduce the machining time
- The same insert can be mounted on both holders for high D.O.C and high feed
- High economical solution due to 10-cornered insert
- Two types of holders are available depending on machining requirements
- AH8015 grade is suitable for difficult- cut materials
Process 2: Drilling (Thin tube sheet)
Benefits
- DMC head for high accuracy drilling provides high hole positioning accuracy and hole straightness
- DMC head does not require a pre hole process even in 12XD drilling, and it reduces machining time
DMC drill head
- Innovative self-centering geometry for smooth drilling and accurate hole tolerance
- Double margins provides superior surface finish and hole straightness
Process 3: Drilling for clad materials
Benefits
- Remove clad material layer by 1.5XD or 3XD drills with high tool rigidity first and then use long drill for further hole depth. By applying this machining method, stability and tool life are improved drastically in clad materials which is difficult to machine
DMC drill head
- Innovative self-centering geometry for smooth drilling and accurate hole tolerance
- Double margins provides superior surface finish and hole straightness
Process 4: Deep drilling (Thick tube sheet)
Benefits
- Apply exchangeable insert type gungrill,DeepTri-Drill for deep drilling process over 12XD hole depth
- Gun drilling is a drilling method to get the highest straightness and hole positioning
- Improves the quality of tubes sheets by preventing hole misalignment and hole bending, which are problems with thick tube sheet
- The best drill for getting high hole straightness
- Chip splitter on the insert creates small chips to evacuate them easily
Process 5: Internal groove by milling
Benefits
- Special head for tube sheet that can produce two grooves with a single pass
- Removing the machining process helps to reduce machining time
- No re-grinding required providing easy tool management
- Wide variety of heads and shanks line up in TungMeister allows flexible combinations and tool lengths for suitable tooling with the highest rigidity
Process 6: Chamfering
Benefits
- For Z-feed chamfering, VCP head with high economical benefits is recommended
- For chamfering by milling, VCA head with high edge density is recommended
VCP head
VCA head
VCP VCA
- No re-grinding required providing easy tool management
- Wide variety of heads and shanks line up in TungMeister allows flexible combinations and tool lengths for suitable tooling with the highest rigidity
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