Production equipment'FED', JSC is equipped with modern high-precision production equipment from global brands.
Turning machine group:
Spinner – Germany
Weiler – Germany
Doosan – South Korea
Star – Japan
Emco – AustriaTurning equipment is represented by ultraprecision Spinner machines with metering system resolution 0.1μm that allows to perform high-precision machining. The machines are designed for hardened workpieces with hardness exceeding 60HRC, maximal diameter 120 mm and length 400 mm. The machines are equipped with counterspindle and complete with robotic manipulator which allows to manufacture intricate pieces in automatic mode.Possibility of parts manufacture in fully automatic mode on Star machines. They are designed for serial high-precision parts manufacture.Doosan turn-milling center machine large machine parts with diameter more than 450 mm and length exceeding 670 mm, perform various high-level technology milling and grooving operations which includes toothing and grooving of geared rim and spline.
Milling machine group:Spinner – Germany
Hermle – Germany
Picomax – Switzerland
Kovosvit – Check RepublikMilling equipment is represented by 5-axis Picomax and Spinner machines. Due to working v power, they are used both for initial forming rough cutting and finishing high-precision machining ensuring precision level up to 0.003 mm. The rotating table allows to machine the most complicated configurations of base members.KOVOSVIT vertical machining centre is used to manufacture large high-precision parts. The machine is designed for precision and speed machining of complicated surfaces.
Milling machine group:Kellenberger – Switzerland
Studer – Switzerland
Reishauer – Switzerland
Micromatic – India
Klein – Germany
ZSS – GermanyStuder and Kellenberger grinding machines are used for production purposes. Since axes are controlled in nano-range, precision level of 0.0001 mm is achieved. Interpolated rotation of head spindle allows to grind parts with complicated shape of threadedurface and manufacture high-precision wedge members.
Electroerosion equipment group::Sodick – JapanVery hard materials are machined with electroerosion equipment which delivers high-quality cutting with precision level of up to 0.001 mm and roughness level up to Ra 0.1. Electroerosion processing allows to solve the most sophisticated technological issues and to process parts of complicated configuration. The significant advantage of this method is absence of thin-walled parts deformation risk.
Super finishing equipment group:Gehring – Germany
Sunnen – USA
Stahli – Switzerland
Thielenhaus – Germany
Allows to perform finishing machining of both internal and external surfaces shape with precision level up to 0.00025 mm.
The following units are used to perform washing:BVLMosel – Germany
Crest – USA
VACUUM-CAST – PolandIn order to ensure high cleanness levels of manufactured parts and nodes, BVLMosel and Crest washing units are used which are equipped with filtering system designed for parts exceeding 10 μm.
Nano-coating and welding
Special technologies floor
Technologies based on vacuum-arc coating method are broadly used in modern machine-building, instrument engineering and other production areas due to possibility to form different functional coatings (hardening, wear-resistant, protective and other) with properties often superior to other coating methods. 'FED', JSC has developed multicomponent, multilayer superhard antifrictional wear-resistant coatings to enhance performance of different parts for units and engines construction, the parts being operated for wear and fatigue in corrosive environments, etc. More than 30 technologies dedicated to multilayer, low-temperature coatings (≤ 150-200°С) to increase reliability and increasing work operation resource of friction couples have been developed in units manufacture.
Avinit C 320 and Avinit C 310 coatings, as well as their technologies were patented in Ukraine, Russia and European Union. The developed technologies have been introduced into 'FED', JSC serial production. The use of developed coatings and their application technologies allows to increase durability and operation reliability of units manufactured and developed by the enterprise by factors. Thus, the use of Avinit C 320-coated sliding valves in hydraulic units allowed to increase the operation resource from 50 to 4,000 hours. The use of Avinit C 310 coatings in friction couples of units increased their operation resource from 200 to 2000 hours.The fllor has developed and patented technologies for Avinit C 320 and Avinit C 310 coating application by vacuum-arc method to enhance reliability and durability of friction couples in units manufacture. The use of developed coatings allows to increase durability and operation reliability of units manufactured by the enterprise. The use of vacuum-plasma precision nitrogen hardening allows to obtain evenly strengthened nitrated case free of products shrinkage while ...preserving initial shapes of parts with precision level up to 1-2 μm which allows to give up finishing grinding. The existing complex of automated equipment for vacuum heat treatment makes it possible to implement high-temperature heat treatment technologies, and hardening technologies using gas cooling, tempering and cold treatment.The installation is designed for the experimental testing of new technologies and the perfection of the existing ones for ion-plasma surface treatment of materials in a glow-discharge plasma of increased density, excited in the hollow cathode. The installation ensures possibility to perform surface treatment of materials in high-density glow-discharge plasma in gaseous environments of different composition (argon, nitrogen, carbon-containing gases and mixtures of th...ese gases), including internal cavities and channels of relevant sizes. The use increased density glow-discharge plasma in ion nitriding processes, carbonitriding makes it possible to reduce the time of hardened cases formation having thickness up to 0.3-0.4 mm by factors in comparison with gaseous furnace technologies, while preserving dimensions of the treated products virtually unchanged and prevent formation of brittle phases on their surface. Consequently, the development of new technologies for surface treatment in increased density plasma is one of the urgent lines of contemporary technologies perfection in a number of industrial production branches.The installation is designed for experimental development of new technologies used for depositing of coatings from conductive and non-conductive materials by HF magnetron targets sputtering. The installation ensures possibility of applying metal coating and their different compounds, including non-conductive materials, as well as non-metals (carbon, fluoroplastic and other). This makes it possible to use the instalation to obtain coatings of various functional purpo...se (protective, hardening, wear-resistant, optical, etc.) and different in composition and structure (monolayer, multilayer, including nano-layer, and nano-structural). Such a diversity of coatings makes the HF method of magnetron targets sputtering and technologies based on its use, one of the most popular in a number of areas of modern production, as well as in the development of new types of coatings and technologies for their production.The installation is designed for experimental development of new technologies used for application of metal and metal-carbide coatings based on molybdenum and tungsten by decomposition of their carbonyls. The installation makes it possible to apply coatings with high homogenity level in thickness on the surface of complex profile items, including blind holes and channels with L/d ˃˃ 1, where L – channel length, and d – channel diameter. Gaseous vapor method used for...coating application is unique in this regard, since it is superior to other methods possibilities, including electrolytic coating application methods. Molybdenum and tungsten high hardness, especially of their compounds with carbon, nitrogen (carbides, nitrides), high durability and low friction coefficients of these compounds at operation in different friction couples, as well as some properties of these metals, makes it possible to refer the coatings made on their basis to the class of materials deemed prospective for use in different nodes and units of modern machine building, aircraft industry and other engineering and production areas. Taking into account the fact that molybdenum and tungsten belong to chrome subgroup, and that the use of 'hexavalent' chrome (CrVI) in accordance with EU Directive (RoHS) is already limited for manufacture of a broad list of industrial products, the development of gas phase technologies of coatings application based on molybdenum, tungsten and their compounds can be deemed in a number of cases as an alternative to a broadly used technology of electrolytic chrome-based coatings application.The main area of argonarc welding by nonconsumable electrode are compounds from carbon, alloyed steels and non-ferrous metals. Argonarc welding can be employed without welding rods for small thickness of metal. This welding method ensures good quality and weld joints formation, to maintain the metal weld penetration in an accurate manner which is very important in case of welding a thin metal when there is only one-sided access to a product surface. welding by nonconsumable electrode is one of the major methods to fuse titanic and aluminum alloys.This method allows to join both the thinnest parts having thickness up to 0.02 μm and parts with thickness up to 20 mm manufactured from different metals and alloys, and their combinations. This welding method is used for welding wire, round and x-shaped bars, shape, sheets, mesh, etc. More often, structures from soft and corrosion-resistant steel are welded, as well as all light alloys and brass. The advantage of this welding method is the absence of necessity to p...rovide welding materials (electrodes, filler materials, flux, etc.), insignificant residual deformations, simplicity and ease of operating the welding materials, connection accuracy (virtual absence of the weld joint), environmental friendliness.Electron-beam welding allows to obtain the following advantages in comparison with other welding methods: - weld joints without shrinkage and deformation of welded parts due to low heat supply and high welding speed; vacuum welding not only prevents metal oxidation in the welding area, but performs degassing of welding pool metal; - possibility to weld a broad variety of different metals with some materials which are not welded by other methods;...- possibility of welding in places and positions not available in other welding methods due to very small diameter of electronic beam and a significant distance to its focusing; - electron-beam welding is an autogenous process and, consequently, does not require filler materials and fluxes which makes it possible to avoid many metallurgical problems. Electron-beam welding installations used in our production, allow to obtain all advantages of electronic-beam welding and are capable of performing superaccurate electron-beam welding at a contemporary technological level.
Equipment for electrical engineering floor
Electrical engineering floor produces sensors and assembly parts needed for completing the products manufactured. The floor has high-tech equipment. The following works are perfomed at electrical engineering floor.It is designed for application of text and graphical images on products surface by laser marking method. Beam transition type is 2-axes scanner, rotary mechanism. Dimensions of active treatment zone is 100x100mm. Market materials: metals, plastics, painted surfaces.Allows to perform metals welding which includes small size parts either in manual mode, or as part of automated production lines. Laser type: solid-state crystal, working in pulse mode.Performed by ytterbium fiber laser. Materials processed: metals, alloys, rubber, textolite. ±30 μm is deemed to be positioning high precision, while repeated positioning precision is ±3 μm.This is performed on layer winding machine which is a fast operating machine complying with modern requirements for reeling-based production. Simplicity of programming ensures fast changeover for another item type while providing production flexibility. The machine functional features ensure all required operations: winding of simple, or sophisticated coils, multi-section coils, non-parallel, or asymmetric windings. The feature of programs storage in memory enhances the operation efficiency. The range of wires diameters that can be used in winding is 0.01-5.0 mm.These are performed using fully automated computerized stattion. Measuring can be performed on different types of samples: bars, stripes, rings, sheets, massive parts, small dimension samples.This is performed using a special testing workbench designed for testing linear movements sensors functioning parameters via stock positioning to a set position and measuring electrical output parameters. The testing workbench ensures the possibility of setting a pre-set voltage, current and frequency followed by stabilization, adjustable load resistance in each winding section, and possibility of multichannel measurings.In order to simulate environmental conditions and to test products by effects of lower and higher temperatures, and to perform temperature treatment and drying of combustible synthetic resins containing volatile solvents, low-temperature chamber and a drying electrical cabinet are used. Temperature range from -85 to +300 С io reached. Unique programming makes it possible to operate in cyclic and constant modes. The furnaces main feature is the ability to implement drying of highly explosive products.
Thermal and metallurgical equipmentThe production facility has its own floor for casting high-quality bronze. The casting floor is equipped with all necessary facilities to produce high-quality ingots using directional crystallization method, and the piston pressure casting method.Horizontal loading single chamber vacuum electric furnaces with overload gas cooling of melting charge are designed for thermal treatment of vehicles parts in vacuum (annealing, drawing-back, air-hardening) and hardening in the inert gas environment, and for carrying out vacuum soldering processes and diffused welding.The production facilities have batch furnace for thermal treatment (hardening, annealing) of a wide variety of structural and instrument steels grades in the inert gas environment. The furnace is capable of choosing hardening medium between oil cooling and inert gas blowing. The furnace is equipped with evaporator to obtain gaseous nitrogen from liquid phase and with refrigeration station to maintain stable temperature of the hardening unit when cooling the parts. T...hermal furnaces with forced atmosphere circulation are designed for thermal treatment under temperatures below the hardening ones (drawing-back, aging, annealing). The floor is also equipped with washing machine to ensure timely and prompt washing of parts from hardening oil remains.
Test-bench equipment which is in operation at 'FED', JSC testing complex.Fuel test-bench is designed for high-performance fuel control units running test, adjustment and continuous tests. This test-bench allows the possibility of testing units with performance up to 3,000 l/min. Test fluid is kerosene ТС-1 or its analog. Manufacturer: 'FED', JSC testing complex.The test-benches are designed for running test, adjustment, predelivery tests, commissioning tests and durability tests of dosing pumps and speed governors . These test-benches allow the possibility of testing units with performance up to 20 l/min. Test fluid is kerosene ТС-1 or its analog. Manufacturer: 'FED', JSC testing complex.The test-bench is designed for testing and adjustment of servo- and proportional valves with flow up to 80 l/min and working pressure up to 210 kgf/cm2. The test-bench is a fully automated equipment. The test-bench operation is fully controlled by computer system which allows to promptly analyze the valves all operating parameters. The test-bench allows to read flow and leak characteristics, to study dependence of pressure difference in control ports on control commands, to carry out dynamic analysis, etc.The test-bench is designed for testing and adjustment of servo- and proportional valves with flow up to 80 l/min and working pressure up to 210 kgf/cm2. The test-bench is a fully automated equipment. The test-bench operation is fully controlled by computer system which allows to promptly analyze virtually all valves operating parameters.The test-benches are designed for running tests, adjustment, predelivery tests, commissioning tests and durability tests of fuel control unitы and working with mathematical model. These test-benches allow the possibility of testing units with performance up to 20 l/min. Test fluid is kerosene ТС-1 or its analog. Manufacturer: 'FED', JSC testing complex.The test-bench is designed for hydraulic tests and cyclic pressure change tests of thermogravimetric analysis. Test fluid: alcohol or distilled water. Manufacturer: 'FED', JSC testing complex.The test-benches are designed for running tests, adjustment, predelivery tests, commissioning tests and durability tests of fuel dosing pumps and speed governors. These test-benches allow the possibility of testing units with performance up to 80 l/min. Test fluid is kerosene ТС-1 or its analog. Manufacturer: 'FED', JSC testing complex.The test-bench is designed for running tests, adjustment, predelivery tests, commissioning tests and durability tests of hydro-motors with variable performance. This test-bench allows for testing units with capacity up to 300 l/min and to carry out tests with following and counteracting loads up to 400Nm. Test fluid is FH51 or its analog. Manufacturer: 'FED', JSC testing complex.The test-benches are designed for running tests, adjustment, predelivery tests, commissioning tests of various modifications dosing pumps units and fuel control units. There is a possibility of testing units with capacity up to 20 l/min. Test fluid is kerosene ТС-1 or its analog. Manufacturer: 'FED', JSC testing complex.The test-bench is designed for adjustment, predelivery tests, commissioning tests of air bleed valves control units at high pressure up to 100 kgf/cm2, as well as adjustment and tuning of positioning sensors. Test fluid is kerosene ТС-1 or its analog. Manufacturer: 'FED', JSC testing complex.The test-bench is designed for vacuum filling of special products. This test-bench allows for creation of relative pressure up to -0.9 kgf/cm2. Test fluid is LZMG-2 hydraulic oil. Manufacturer: 'FED', JSC testing complex.The test-bench is designed for products pressing with FH-51 hydraulic oil. This test-bench allows for products pressing with effort up to 700 kgf/cm2. Test fluid is FH-51 hydraulic oil. Manufacturer: 'FED', JSC testing complex.This test-bench is designed for washing of bleeds, valves, units of fuel control units and other fuel-related products. Process pump maximal capacity equals to 20 l.min., maximal working pressure – 100 kgf/cm2. Test fluid is kerosene ТС-1 or its analog Jet A1. Manufacturer: 'FED', JSC testing complex.The test-bench is designed for running tests, parameters process control and commissioning tests of fuel control units pumping units. Tests at different drive shaft rotational speeds, flow measuring up to 80 l/min., measuring pressure up to 100 kgf/cm2 are performed using this test-bench. Test fluid is kerosene ТС-1 or its analog Jet A1. Manufacturer: 'FED', JSC testing complex.The test-benches are designed for performing adjustments, predelivery tests, commissioning tests and durability tests of fuel metering units. These test-benches are used for process pumps running tests, measuring pressure up to 100 kgf/cm2, measuring flow up to 20 l/min. in different cavities of a product. Test fluid is kerosene ТС-1 or its analog. Manufacturer: 'FED', JSC testing complex.Thermal-vacuum chamber is used to simulate environmental conditions. A variety of objects can be subject to high and low temperatures in the range from +120°С to -70°С thermal-vacuum chamber, besides, pressures starting from atmospheric to 1.33 MPa can be created in the working volume.Heat chamber is used to simulate ambient conditions. Various objects can be subject to high and low temperatures in the range from +120°С до -70°С.The heat chamber is used to simulate ambient conditions. A variety of objects can be subject to high and low temperatures in the range from +180°С to -70°С thermal-vacuum chamber, besides, pressures starting from atmospheric to 1.33 MPa can be created in the working volume.
'FED', JSC possesses:The test-bench is designed for valves washing. Test fluid is kerosene ТС-1 or its analog. The following hydraulic components are the test-bench counterparts: - pressure gauges 0…60 kgf/cm²; - hydraulic pump Q=25 l/min., Р=0…30 kgf/cm² Manufacturer: 'FED', JSC testing complex.The test-bench is designed for casings hydraulic tests. Test fluid is hydraulic oil FH51 or its analog АМГ10. The following hydraulic components are the test-bench counterparts: - pressure gauges 0…60 kgf/cm²; - hydraulic pump Q=25 l/min., Р=0…150 kgf/cm² Manufacturer: 'FED', JSC testing complex.The test-bench is designed to perform transfusion of electrical hydraulic actuators sliding valves. Maximal consumed flow for sliding valves transfusion equals to 30 l/min, maximal working pressure created by the process pump is 250 kgf/cm2. Test fluid FH-51. Manufacturer: 'FED', JSC testing complex.The test-bench is designed to perform transfusion of fuel control units. It is allowed only to perform tests with process pump maximal capacity up to 30 l/min., pressure up to 100 kgf/cm2, and control of pressure drop between working cavities. Test fluid is kerosene TC-1. Manufacturer: 'FED', JSC testing complex.