Customers & Case Studies
At Abrasive Blades, we have the ability to analyse the application as a whole.
From advising on the correct machine settings and optimising the cutting process, through to selecting the best wheel specification to give maximum wheel life and best quality of cut.
We can select the correct grain size and type, together with the correct bond formulation and, if a reinforced construction is needed, we can choose from various glass fibre reinforcing cloths in a range of formats to give a wheel that performs to the highest of standards.
By producing cut-off wheels that give maximum wheel life and ultimate finish quality we have been able show our customers considerable savings in their cutting costs.
The following case studies are actual examples where we have achieved this .
Case study:
- Manufacturer of vacuum cast aerospace alloys
- Manufacturer of SG iron round and square section bar
- Manufacturer of stainless steel billets and slabs
- Manufacturer of cast iron products for the automotive industry
- Manufacture of stainless and carbon steel cast components using the investment or ‘lost wax’ process
1) Manufacturer of vacuum cast aerospace alloys
Application: Dry cutting of 75mm diameter bars using an automatic cut-off machine with an oscillating head.
The customer had been using 457mm cut-off wheels, which although cutting well, were often breaking well before the maximum wheel depth had been used.
Having analysed the problem and following trials, Abrasive Blades was able to construct a wheel that was able to cut down to the minimum diameter permitted by the machine without breaking.
Even after a small additional cost per wheel, the customer has seen considerable cost savings.
2) Manufacturer of SG iron round and square section bar
Application: Bars up to 300mm diameter are partially cut and then broken off using hydraulic rams. Cutting is by manual chop stroke saws with lateral traverse using 610mm reinforced cut-off wheels.
The competitor's product was typically producing around 5 cuts per wheel on 250mm diameter bar.
Following comprehensive trials, Abrasive Blades was able to provide a cut-off wheel, which is now constantly producing 9 cuts per wheel on the same material.
This has resulted in a cost saving of around 45 per cent.
3) Manufacturer of stainless steel billets and slabs
Application: Wet-cutting of standard sized test pieces on a manual chop stroke cut-off machine using a 300mm diameter reinforced cut-off wheel.
The original supplier was providing a wheel, which was giving 9 to 10 cuts before the wheel had worn out completely. By making changes in the abrasive grain and bond structure Abrasive Blades produced a wheel with a vastly improved performance, which is now gives 35 to 40 cuts per wheel..
This fourfold increase in life has lead to major cost savings for the customer.
4) Manufacturer of cast iron products for the automotive industry
Application: Grinding flash lines from cast components using a 63mm grinding wheel on a hand held air grinder.
Tests were carried out and the results showed that the Abrasive Blades grinding wheel gave over 2 and a half times the life compared to the competitor's wheel. There was also a substantial reduction in operator down time as the wheels did not need to be changed as often.
By changing to the Abrasive Blades grinding wheel the customer has reduced his spend on this item alone by over 57 per cent and has seen a considerable increase in productivity.
5) Manufacture of stainless and carbon steel cast components using the investment or ‘lost wax’ process
Application: Cutting castings from runner systems on a manual push saw using a 406mm reinforced cut-off wheel.
Following an extensive testing programme, Abrasive Blades has developed a cut-off wheel that has not only shown an increase in performance by up to 40 per cent but also stays straighter in the cut thus resulting in improved durability.
By changing to Abrasive Blades, the customer has seen cost savings from enhanced wheel performance and increased productivity. In addition they have experienced an improvement in continuity of supply.
What we have achieved for clients across the metallurgical, automotive, aerospace, steel, foundry and construction industries, we can achieve for you. Please call +44 (0) 1923 223 248 for an initial discussion or complete the online enquiry form provided. We will be delighted to advise you on the options available to you and provide a competitive quotation.
