Precision Grinding and Cutoff Manufacturing Case Studies
11.04.2021
Case Studies Orthopedic Devices Case Studies
Current ProcessKirschner wires, also commonly known as K-wires, are ground using a manual OD grinder.ChallengesLow production output, as only one wire can be ground at a time. Changeover between wire diameters is time-consuming, delaying production. Grinding can leave burrs requiring secondary processes to deburr, lengthening p...
11.04.2021
Case Studies Orthopedic Devices Case Studies
Current ProcessKirschner wires, also commonly known as K-wires, are ground using a manual OD grinder.ChallengesLow production output, as only one wire can be ground at a time. Changeover between wire diameters is time-consuming, delaying production. Grinding can leave burrs requiring secondary processes to deburr, lengthening p...
10.04.2021
Case Studies Tube Grinding & Cutoff Case Studies
Current ProcessA high-powered laser beam cuts the tubing by melting it leaving a rough edge and slag. Tubes and other parts are typically cut one at a time limiting production rates.ChallengesHeat sensitive applications may limit the use of the laser for cutting. Laser cutting leaves recast and heat-affected zones, affecting the tube’s quality an...
10.04.2021
Case Studies Tube Grinding & Cutoff Case Studies
Current ProcessA high-powered laser beam cuts the tubing by melting it leaving a rough edge and slag. Tubes and other parts are typically cut one at a time limiting production rates.ChallengesHeat sensitive applications may limit the use of the laser for cutting. Laser cutting leaves recast and heat-affected zones, affecting the tube’s quality an...
09.05.2021
Case Studies Fastener Grinding Case Studies
Challenge: A tier one automotive fastener supplier needed to grind bolts for a major automotive company automatically at high volume, with a high degree of precision. The customer’s existing process was outsourced and was running one part at a time, resulting in a higher cost for our customer. In addition, quality and consist...
09.05.2021
Case Studies Fastener Grinding Case Studies
Challenge: A tier one automotive fastener supplier needed to grind bolts for a major automotive company automatically at high volume, with a high degree of precision. The customer’s existing process was outsourced and was running one part at a time, resulting in a higher cost for our customer. In addition, quality and consist...
09.04.2021
Case Studies Machine Upgrades Case Studies
Current Process:
Narrow work wheels prevent generating tapers over 4″ requiring multiple setups to generate the shape. Highly skilled technicians are required to ensure proper setup. Upper and lower slides are strapped, preventing the regulating wheel and work rest blade from being adjusted independently. Wheel dressing is applied manually, which...
09.04.2021
Case Studies Machine Upgrades Case Studies
Current Process:
Narrow work wheels prevent generating tapers over 4″ requiring multiple setups to generate the shape. Highly skilled technicians are required to ensure proper setup. Upper and lower slides are strapped, preventing the regulating wheel and work rest blade from being adjusted independently. Wheel dressing is applied manually, which...
08.04.2021
Case Studies Medical Needle Case Studies
ChallengeConverted OD grinders with custom tooling and soft grinding wheels all of which wear at a high rate. Setup and changeover time is significant and requires extensive mechanical adjustments. Parts, in most cases, must be taped for handling requiring additional steps in the production process. Primary cut leaves a large ID bu...
08.04.2021
Case Studies Medical Needle Case Studies
ChallengeConverted OD grinders with custom tooling and soft grinding wheels all of which wear at a high rate. Setup and changeover time is significant and requires extensive mechanical adjustments. Parts, in most cases, must be taped for handling requiring additional steps in the production process. Primary cut leaves a large ID bu...
07.04.2021
Case Studies General Case Studies
ChallengeParts are cut using abrasive cutting saws, conventional abrasive grinding, wire EDM or laser cutting; slow processes resulting in long cycle times. Potential to expose material to high heat leading to heat affected zones, recast, and slag. Requires secondary process to deburr parts and remove any surface debris which reduces productivi...
07.04.2021
Case Studies General Case Studies
ChallengeParts are cut using abrasive cutting saws, conventional abrasive grinding, wire EDM or laser cutting; slow processes resulting in long cycle times. Potential to expose material to high heat leading to heat affected zones, recast, and slag. Requires secondary process to deburr parts and remove any surface debris which reduces productivi...
06.04.2021
Case Studies Medical Device Case Studies
ChallengeThe arthroscopic shaver teeth are commonly produced by conventional abrasive grinding, wire EDM, or laser cutting; slow processes resulting in long cycle times. EDM and laser cutting burn away the metal at high temperatures leaving changes to the metal surface including a heat affected zone, recast, and slag. Laser cut...
06.04.2021
Case Studies Medical Device Case Studies
ChallengeThe arthroscopic shaver teeth are commonly produced by conventional abrasive grinding, wire EDM, or laser cutting; slow processes resulting in long cycle times. EDM and laser cutting burn away the metal at high temperatures leaving changes to the metal surface including a heat affected zone, recast, and slag. Laser cut...
05.04.2021
Case Studies Tube Grinding & Cutoff Case Studies
ChallengeTubes are cut one at a time using a standard abrasive cutting saw which leaves burrs. Requires secondary process of wire brushing and tumbling to deburr tubes and remove any debris. Older machines have poor accuracy and outdated safety features. Debris from abrasive cuts cause frequent maintenance issues.Design a process that can cut m...
05.04.2021
Case Studies Tube Grinding & Cutoff Case Studies
ChallengeTubes are cut one at a time using a standard abrasive cutting saw which leaves burrs. Requires secondary process of wire brushing and tumbling to deburr tubes and remove any debris. Older machines have poor accuracy and outdated safety features. Debris from abrasive cuts cause frequent maintenance issues.Design a process that can cut m...
