REIKA GmbH & Co. KG, member of the Graebener Group, recently received an order to supply a chamfering line to the largest
international steel group for one of their seamless tube mills. The turnkey line consists of two chamfering machines and an
integrated transport system and will be assembled in a mill for hot-rolled tubes in Romania.
This new order resulted in part from several jobs in the past, with the latest very successful deliveries of straighteners to a
French subsidiary and cutting lines to the group’s Czech tube mill. As the customer is really satisfied with the quality and
the performance of the REIKA products, those responsible recommended REIKA to their corporate headquarters.
On the other hand, the company already convinced its customers with their high precision and rugged chamfering lines,
including those, competitors of the steel group. The customers were also thrilled by the outstanding reliability of the systems,
being a guarantee for high quality tube ends and tool lifetime. So the customer’s decision was clearly in favor of REIKA as
a turnkey supplier for the whole system.
The chamfering line will provide seamless pipes with a diameter of 114 ( 4.5 " ) to 406 mm (16") and a wall thickness
from 4 to 35 mm with bevels for the oil and gas industry. The tubes meet API and ASME standards, are 5 to 15 m long
and have a unit weight up to 3,500 kg. A complete customized tool package will be delivered along with the line, consisting
of chamfering heads, tool holders and clamping tools.
REIKA chamfering lines provide facing, internal and external chamfering to welded and seamless tubes in accordance with
DIN, API, ASME or ANSI standards. The machines can be supplied in single or double-sided design and can be integrated
online into the material- and the entire tube mill work flow.
REIKA chamfering lines are designed for 2 ½ to 24” diameter tubes. All lines can be equipped with special custom-made
features, such as advanced CNC control, a detailed target/actual diameter measurement and a fully automatic tool calibration,
resulting in high cutting speed and short cycle and set-up times with flexible, customized tool systems.
Focus on profitability
Central America’s largest pipe producer receives first RingSaw®
It was for economic reasons, leading one of the world's largest pipe manufacturers late last year to make a
fundamental decision in favour of REIKA’s RingSaw®. In other words, all production facilities of the leading pipe group
should be gradually equipped with the innovative concept of the inside tooth saw blade.
The first machine is now scheduled to be shipped for coupling production with destination Central America.
The task was not easy, REIKA Managing Director Hans-Jörg Braun remembers well. "The machine is designed
to cut blanks for premium pipe couplings within the diameter range 3-7" from the long tube." The wall thickness is
between 0.5 and 2" and the length of the couplings is 130 to 350 mm, made from heat-treated, high-strength steel
to API 5CT standard with a strength of up to 1200 N/mm ².
The cut blanks shall be clamped precisely and without jamming to the downstream turning or threading machines.
" The customer quickly realized the process advantages of our RingSaw®, Braun says." The rectangular and almost
burr-free cut is not the only advantage of our conceptual design, that ensures exact and absolutely clearance-free
location of the blanks. Another big advantage of the RingSaw® : heavy comma shaped chips and no magnetization
during the cutting process, which will not leave sticky chips on the pipe material. They will be discharged directly
to the chip conveyor.
In total, these advantages save rework and increase the number of blanks, leading to around 150 parts per hour
with the RingSaw®. Another profit is the turnkey handling system for ingoing tubes upto 15 m length.
REIKA’s RingSaw® offers numerous additional advantages with its internal tooth cutting tool, equipped with four-
side cutting inserts, compared to conventional saws. The name says it all: the inserts can be used up to four times
before they are worn out. The RingSaw® is equipped with a tool monitoring system to detect tool wear and breakage
and to ensure optimum cutting quality.
The inserts can be screwed into the tool carrier, so complex and time consuming presettings on the machine or on
the cutting tool are avoided. The run times of the tools are much longer, lifetimes correspondingly lower.
And last but not least, there is no wear on the tool carrier.
Keyword cost : The follow-up cost are lower than with competitive concepts due to our machine concept.
" The rotating tool is more comfortable on the machine compared to a cutting tool cutting from outside and the
centrifugal forces are greater" explains Hans-Jörg Braun. Therefore, the follow-up costs are lower, as there are
no forces which may act on the lunettes.
Long tubes will be delivered to the machine via a loading rack with gripper system and fed into the correct position.
The measuring system located in the inlet area automatically registers the tube diameter at the entry side – so
diameter mixup can be avoided – .
First of all the “as rolled” tube end will be cut first and discharged to a separate scrap recycling bin. If there are
colored tube defects on the ingoing tube, they will be cut out and also discharged to the scrap recycling bin.
The cut blanks are automatically removed by a robot, automatically measured and marked on an external station
to be finally stacked into a container according to customer specification.
" Again, we are guided by the customers demands to accelerate the production process as much as possible. "
Hans-Jörg Braun says. So again, REIKA’s focus on profitability is always in first place.