Weld Removal

Featured End User 1

Bio: Heavy plate fabricator of agricultural and construction equipment.

Concerned about their current source due to a supply issue, we were given the opportunity to do a complete grinding evaluation for this End User. Upon our conclusion, we found they were using ceramic products, such as Resin Fibre Discs, Belts and Quick-Loks. Ceramic, for most mild steel applications, is an oversell due to its high initial cost compared to the close performance factors of zirconia. We demonstrated a 90% performance comparison for 1/2 the cost of ceramic on all abrasive products. This resulted in a projected $37,000 cost savings, of which 99% was captured within the first year. Due to our continued efforts, we were allowed to continue our cost savings approach at 4 more of their manufacturing facilities.

Solution: Mild steel, during the grinding process, does not generate enough heat to justify the cool cutting action of ceramic. The construction of ceramic grain is costly, compared to zirconia. Since heat generation is not a concern when removing welds on mild steel, zirconia is the grain of choice. Zirconia has a fast cut and similar life when compared to ceramic, at roughly half the cost.

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Deburring and Flash Removal

Featured End User 2

Bio: Progressive die stamping company.

After continuously using several different Belts to achieve deburring and finishing requirements, this End User was interested in a new product that would eliminate product changeovers and machine downtime.

Solution: By suggesting a compact grain, we were able to exceed all product expectations. Since individual compact grains are a cluster of one grit, products are expected to last at least 10 times longer than other abrasives. Using our compact grain belts, a performance increase of 15-to-1 was achieved, compared to the conventional abrasives previously used. Our recommended belts were more versatile and the suggested switch resulted in less changeover and more production time, combined with a substantial cost savings due to the increased performance.

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Metallic Surface Finishing

Featured End User 3

Bio: Fire truck manufacturer.

During our visit to this End User, we immediately noticed several processes on several different materials. They wanted a formidable product with the versatility to satisfy all applications.

Solution: Within the walls of our in-house lab, we have developed an aluminum-specific product with great success. Our Development Team found a unique way of incorporating a grinding aid into the grain structure of existing abrasives. Our 3X Performance Coated Products gave this End User faster cut and longer life compared to previous products. With this enhanced product, they were able to cut 5 manufacturing processes down to 3. In addition, this End User consolidated 9 separate products into just 4. In the end, their initial cost savings totaled nearly 6 figures!

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More Deburring Studies...

Grove Crane
Producers of mobile hydraulic cranes.

Symmetry Medical
Supplier of contract implants, instruments and cases to orthopedic medical device manufactures.

Stanley Hand Tools
Manufacturer of quality hand tools.

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Hartzell Propeller, Inc.
Designs and manufactures propellers for light aircraft up to regional airliners.

Whirlpool
Manufacturer of home and business appliances.

Moeller Manufacturing Company, Inc.
Producer of stamping and die components.