Back TECHNOLOGIES

BelOMA-MMW named after S.I.Vavilov Public Corporation has great  production capabilities concentrated ­ in special-purpose production lines, such as foundry, machining, optical, polymeric material processing, stamping shops, electroplating shops and paint and varnish shops, assembly shops and tool shops. BelOMA has specialized production areas for check of mouldings on tightness and their vacuum impregnation in sodium silicate composition, production areas on manufacturing of printed-circuit boards, electronic modules, optional equipment, welding, woodworking etc.
In foundry at manufacturing of the mouldings the following methods of molding are being applied:
· die casting;
· investment casting;
· gravity die casting;
· sand casting;
One of the basic trends in foundry is manufacturing of mouldings by die casting method. A high technological level has been achieved in production of mouldings of aluminium-silicon, aluminium-silicon-copper alloys and zinc alloys. The weight of the parts being casted - from several grams to 12 kg. Heat of metal is being executed in induction furnaces with mains frequency of IÀÒ-04 with refined double flux, degasing pellets and filtration of the molten metal through a special grid. Production of mouldings is being executed by means of die casting machines with closing force from 160 to 1100 t/forces produced by "BUHLER" (Switzerland), «ITALPRESSE» (Italy), «VIHORLAT» (Slovakia) firms.
In 2003-2005 six new die casting machines produced by "BUHLER" Firm (Classic-26D, Classic-34D, Classic-42D) which are controlled by computer have been  bought. They are equipped with the system of sensors for a feedback which allows to supervise and correct in real time all parameters of technological process according to the stated programme.
At die casting workshop castings of body parts of gas meters, pneumatic devices of brake systems of heavy haulers, sighting devices are being produced.
95 % of the castings being produced are subject to tightness control at excess pressure up to 10 atm., at that most of castings have wall thickness within the range of 2 ÷ 2,5 mm.
The monthly flow of mouldings varies (depending on the casting nomenclature) within 70-80 tons. The nomenclature of the mastered and being produced by die casting method castings amounts to 1100-1250 names.

Investment Casting allows to receive workpieces with minimum machining. As a rule, the allowance for machining does not exceed 0,7-1,2 mm. The nomenclature of the mastered and being casted parts amounts to 700-800 names. The monthly flow of castings varies (depending on the casting nomenclature ) within the range up to 2 tons. At the enterprise castings of carbon structural steel, chrome-nickel (stainless) steel and heat-resistant steel, copper-based alloys are being produced. Heat of metal are being executed in high-frequency induction furnaces IST-0.16.
The weight of the castings – from several grams to 3,5 kg. The original technology with application of "Sialit-20" as a binding agent instead of earlier used ethyl silicate is being applied at the workshop.

Gravity Die Castingis being applied for production of complex body parts of  aluminium-silicon alloys with additives of magnesium and manganese by method of gravity casting of molten metal with subsequent heat treatment. Heat treatment of castings allows to increase strength characteristics by 30 %. The weight of castings amounts to 8 kg. Heat of metal is being executed in crucible furnaces. The equipment produced by the firms of the CIS countries is being applied.

Sand Castingis basically used for production of castings for repair needs.
Controlof conformity of actual values of physical and mechanical characteristics and chemical composition of the material of workpieces and parts is being provided for by functioning of a complex system of metallographic research which takes place in spectral, X-ray examination and metallographic laboratories.

Processing of polymer materials is being performed by die casting method and compression. Materials of 24 kinds, both thermoplastic of various groups and brands, as well as thermosetting (karbolits of various brands, fiberglass) are being applied. The most frequently used materials are shock-resistant polystyrene, ÀBÑ, Hostaform, Fortron, polycarbonate. There is a site of processing of rubber mixes of various brands. The process of production of polymeric optics has been mastered. The maximum weight of castings - 1-1,2 kg. The nomenclature of the parts being produced by this method amounts to 870-950 names. The parts made of thermoplastic polymers and rubber mixes are being widely used in such products as gas meters,  consumer goods, brake system units.
The parts of thermosetting polymeric materials and rubbers are being produced on hydraulic presses of vertical type with tonnage of 160 tons, the press produced by  "Hydropress" Plant, Russia. The parts of thermoplastic polymers are being produced by thermoplastic machines produced by «ENGEL», «ARBURG», «IDRA», «HEMSCAIT», «KUASY» Firms. In 2008 four thermoplastic machines produced by  Baranovichsky Engineering Plant of ATLANT Close Corporation.

Pressing - Blank Production has possibility of production (by tool set of the customer or by manufacturing of own tool set) pressed parts of sheet material with a  thickness from 0,06 mm to 5 mm, with accuracy of performance of the sizes up to 11 quality class. Blank production is equipped with the following equipment:
· mechanical presses with tonnage from 6,3 tons to 100 tons which allows to carry out all spectrum of technological operations of cold sheet stamping: chipping, notching, punching, bending, stretching, moulding;
· automatic presses with tonnage of 10 tons which allow to carry out notching of the parts with the size up to 40 mm of the tape with a thickness up to 1 mm with a speed from 150 to 450 blows per minute;
· stamping press with tonnage of 160 tons, 250 tons which allow to carry out stamping, flattening, notching, grooving application;
· double action presses with tonnage of 63 tons, 100 tons which allow to carry out deep drawing of parts of various shapes with a height up to 180 mm, diameter up to 200mm and thickness up to 2 mm;
· sheet bending machines and sheet bending presses with tonnage up to 100 tons which allow to carry out bending of the parts with a length up to 2,5 m;
· automatic cutoff machines which allow to execute cutting-off of rounds with diameter up to 350 mm,  including the bandsawing automatic machine produced by "PILOUS" Firm, Czechia, which allow to cut blanks with diameter up to 240 mm with accuracy up to 0,2 mm, as well as guillotine  scissors for cutting of flats with a thickness up to 6 mm and cutting length up to 3 metres;
· tumbling equipment which allow to remove burrs from the parts by abrasive powder or porcelain prisms and polishing equipment which allow to execute  various polishing of the parts (including foundry) with dulling of sharp edges by means of porcelain and steel balls.

There is a division of step-by-step stamping which allow to carry out the parts of complex configuration by small series without tool set and without long-term preproduction. A special universal tool set for cutting-off, punching, notching, chipping, bending etc. as well as beaders, forming rolls with a width up to 1 m, drilling, thread-cutting, cleaning machines and other equipment are being used in the division.

Machining Process Production is equipped with universal, specialized and special machine tools, including turning, milling machines, NC horizontal borers and machining centers which allow to produce complex machining of the parts under  conditions of small-scale production as well as in series. The material of the parts being processed – structural, stainless and heat-resistant steels, nonferrous materials alloys, including titanium and magnesium alloys.

Kinds of the parts being processed:

· cases, covers, brackets, boards, cams and other parts with the sizes up to 500 mm; various parts of the type of "body of revolution» with diameter up to 200 mm and length up to 600 mm; accuracy of the surfaces being processed -  7-9 quality class,  deviation from the geometrical shape - 0,005-0,01 mm;
· high-precision measuring, flat guideways and round beams with a length up to 1500 mm and diameter up to 200 mm, cumulative pitch error on a length of 1000 mm – up to 0,015 mm, geometry deviation  - up to 0,02 mm on the whole length;
· parts of gyroscopes with diameter up to 100 mm;
· parts of various configuration with diameter from 0,5 mm to 40 mm;
· tooth gears (spurs and spiral gears) with the module from 0,2 mm to 3 mm and diameter up to 300 mm, degree of accuracy 7-9, as well as worm gears and worms.

High-efficiency technological process of final polishing of dead-end holes and  through holes in the parts made of aluminium alloys and steels by means of roller burnishers is being applied at the Enterprise. The characteristics of a surface being processed: roughness before rolling-off - Ra =0,8, after rolling-off - Ra =0,2-0,63, accuracy of the holes being processed - 8-10 quality classes.
The sites of processing centres available at the Enterprise allow to execute  complex machining ­ of body parts with ­ dimensions up to 500 mm. The sites ­ are equipped with high-efficient ­ vertical processing ­ centres of the new generation of model DMU 60 P (manufacturer - DECKEL-MAHO Firm, Germany), models VF-2DHE; VF-3DHE (HAAS Firm, USA), as well as horizontal processing centres of models IR 500PÌF4, IR 320PÌF4, ÍÐ-5, ÌS032.
Along with traditional NC machines of models 16À20F3, 16B16Ò, IÒ-42, ÒPÊ-125 the new NC turret machines of the models SL-10HE; SL-20HE (HAAS Firm, USA) and ultraprecision NC lathe of model PD/B-MS-V3 (SPINNER Firm, Germany) operate at the Enterprise. The fact that machines of models SL-20HE; PD/B-MS-V3 are equipped with power tools allows to execute complex final polishing of high-precision parts of the lenses with execution of finishing operations.

Optical Production has great production capabilities to produce potentialities quickly and with high quality optical parts of glass and crystals in necessary quantities:
· lenses with spherical and flat surfaces with diameters from 3 mm to 200mm:
- accuracy of manufacturing of working surfaces - up to l/10;
- radius range - from 2mm ad infinitum;
- thickness in the centre to diameter ratio – up to 1:20, edge thickness – up to 0,3 mm.
· cemented optical parts:
- diameter of lenses – up to 100 mm two-and three-component;
- glass linear expansion factor difference  - up to 66x10-7 ºÑ-1;
- cementing is being executed both by traditional technology as well as with application of the technology of ultrasonic hardening which provides for manufacturing of the high accuracy units resistant to effect of mechanical and climatic factors.
· plates and wedges:
- diameter up to 200 mm, thickness to diameter ratio – up to 1:30, surface accuracy – up to l/20, nonparallelism – up to 1”, selected wedge angle deviation - up to 2”.
· prisms:
- the following kinds of prisms are being produced: rectangular, rhombic, pentaprisms - and semipentaprisms, Dove prisms, Schmidt, Abbe, Pehan prisms, cemented cubic prisms;
- the sizes of faces - from 3 mm to 100 mm.;
- angle accuracy  - up to 2”;
- pyramidality - up to 5”;
- surface accuracy - up to l/20.
· angular and linear grids and scales:
- methods of manufacturing - engraving-dividing and photolithographic;
- maximum sizes of a substrate for grids – up to 150 mm.;
- size of image elements - from 8 microns.;
- transmission density of a coating - up to 3 D.
· coatings:
- method of production - vacuum and chemical;
- spectral range - visible, close-range IR;
- kinds of coatings: antireflecting, including achromatic; mirror, including high-reflecting dielectric; conducting; beam-splitting; interference filtering coatings.
The coatings are being applied on the surfaces of the above-mentioned  nomenclature of the parts. The parameters of coatings correspond to the requirements of the modern instrument making.

Galvanic and Paint and Varnish Production allows to apply various protective and protective decorative and functional coatings on metal and nonmetal parts:
· galvanizing (with iridescent, colourless and black passivation) on the parts with overall dimensions up to 500x400x150 mm;
· nickel plating (semishining and matte), chromium plating on the parts with overall dimensions up to 600x400x200 mm;
· stainless steel electropolishing on the parts with overall dimensions up to 350x250x250 mm;
· anodizing of aluminium alloys with painting in pigments (black, «in simulation of gold») on the parts with overall dimensions up to 500x350x400 mm;
· chemical oxidation of steel and aluminium alloys on the parts with overall dimensions up to 600x450x350 mm;
· any paint and varnish coatings on the parts with overall dimensions up to 800x800x1000 mm, on a site of large-sized painting - with overall dimensions up to 2900x3900x2700 mm;
· application of powder polymeric enamels on the parts with overall dimensions up to 1700x1000x1500 mm.
Tool Production is staffed with the qualified professionals and modern equipment (including processing centres of models DÌU5OT, DÌU60Å produced by  DECKEL - MAHO (Germany), model VF-3 produced by HAAS Firm (USA) which   allows to produce fixtures of any complexity and nomenclature (die casting moulds, die molds for processing of plastic and rubbers, stamps, machine accessories and test tools and equipment and the tool) as per the design documentation developed by the experts of the Enterprise, or as per design documentation of the customer.
Among traditional kinds of heat treatment being carried out in tool production it is necessary to note such kinds of operations as nonoxidation hardening and tempering of the parts in the environment of the dissociated ammonium; vacuum heat treatment; surface processing, including isometric hardening  in molten salt on the basis of niter.
Assembly Works are being carried out on conveyors and in individual order by the specialized by kinds and series of the products being manufactured assemblings, as well as by the specialized assembly floors of the corresponding shops.
Along with the centralized divisions of the Enterprise the assemblings have their own divisions of machining process (including engraving division), wiring (including surface cabling) and the laboratories which provide for complete cycle of assembly and acceptance tests of the products being manufactured within the framework of one production.
For execution of the works which demand ensuring of special cleanliness there are special premises with a microclimate and content of maximum 1000 dust particles with the size of 1 microns per 1 l of air;
The equipment of assemblings and qualification of the executors allow to provide for:
· alignment of the linear sizes, parallelism, perpendicularity with the accuracy up to 0,01-0,001 mm;
· adjustment and check of optical characteristics and parameters;
· adjustment and check of analogue and digital electronic functional units of the devices;
· tightness of the units and devices under pressure up to 10 atm.
The assembling of gas meters is equipped with the specialized equipment which allow to produce gas meters of various dimension type.

Kinds of equipment being used for production of gas meters:
· automated test complex equipped with multiposition benches which enable to carry out check of the basic relative error at consumption from Qmax-10m3/h up to Qmin-0,016 ì3/h. Reading is automated and is being carried out by means of gauges with subsequent calculation and display on PC. The range of the permissible basic relative error of the bench within the range of consumption: Q min up to 0,1, Qnom-1 %, above 0,1 Q nom up to Qmax-0,5 %;
· multiposition bench of tightness test equipped with the unit for drying of compressed air with cooling named «BOGE KOMPRESSOREN»;
· the equipment for control and ensuring of all-the-year-round special climatic conditions;
· air-conditioning centre.
The temperature of 20ºC-21ºÑ is being provided for by IR radiators produced by the Enterprise with automatic mode maintenance.
The central test station operates at the Enterprisewhich provides for products testing for resistance to influence of external factors:
· temperature from - 60ºÑ to + 100ºÑ;
· relative humidity up to 98%±2 % at a temperature from 20ºÑ to 50 ºÑ;
· residual pressure up to 10 mm of mercury;
· vibration within the range  of 5÷12500 Hz with acceleration of 10g÷350g;
· shock loads 30g÷110g;

There is also a complex of research-and-production laboratories: spectral, mechano-metallographic, optical, chemical, galvanic and paint and varnish coatings, X-ray examination, industrial sanitation, linear - angular measurements.
 
Makayonok St.23, 220114, Minsk, Republic of Belarus