Grinding wheels for manual operations

Compared with conventional resin-bonded grinding wheels, Engis says that its Dia-ForZ range of diamond-plated wheels offers many significant benefits, including greater operator safety. For instance, as the diamond grit is electroplated to the metal body, the wheel cannot fail, break or come apart due to abuse. This factor is particularly important in hand-tool operations, where it is easy to drop the grinder, or the machine over-speeds due to the failure of the governor.

Dia-ForZ diamond-plated wheels last longer and cut faster than aluminium oxide and zirconia alumina alternatives. Furthermore, because diamond stays sharper for longer and cuts faster, less force is required to remove imperfections on castings, leading to enhanced operator ergonomics.

The wheels do not need to be dressed, thanks to greater grit exposure than is seen in conventional wheels. In addition, as the wheel does not wear like a conventional wheel, there is no loss of form or peripheral speed, resulting in less dust.

The Dia-ForZ range is available in portable Ty 1, Ty 6 and Ty 27 versions, as well as cut-off wheels, burrs and wheels for robotic cells.

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Metro Madrid selects Guyson

Finishing equipment manufacturer, Guyson International, with its Spanish distributor Materias Primas Abrasivas, has recently installed a Guyson Euroblast 8 air-wash cabinet into Metro Madrid’s main maintenance workshop for removing dust particles and other contaminants from the braking systems of underground trains.

The health, safety and wellbeing of Metro Madrid’s maintenance staff was the primary concern when selecting the system. Guyson’s Euroblast 8 blow-off cabinet provides a sealed work chamber for safely air washing braking systems utilising a hand-operated air-wash gun. Removing dust, dirt and debris from underground train braking systems is a daily maintenance task for the Metro team, so keeping a clean and safe environment without leaking dust, dirt, debris or noise into the work area is essential.

In terms of design, the cabinet is fitted with two air-wash guns – high pressure and low pressure – which the operator can easily select depending on the type and/or volume of contaminant: high pressure for the aggressive removal of caked-on dust, or low pressure for lighter material.

In order to retain high visibility during the brake cleaning process, a Guyson C400 cartridge dust collector connects to the rear of the cabinet, effectively removing the loosened dust and airborne particles into the collection bin so they can be safely disposed of, while maintaining a clean working environment.

Due to the numerous types of braking systems, some of which are extremely heavy, the Madrid Metro maintenance team selected the Euroblast 8 blow-off system with optional side-loading turntable, which enables large/heavy items to be loaded directly on to the turntable via crane or forklift. The turntable pushes into the cabinet, with hand rotation providing all-round access during the cleaning process.

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Remote maintenance solutions

The potency of remote maintenance and customer assistance – especially harnessing the power of smartphones – has never been demonstrated more forcibly than during the past year when the COVID-19 pandemic has forced lockdowns across the globe. However, the United Grinding Group has increasingly used technology to support its worldwide customer base and, in many cases, keep machines running with minimal downtime.

According to United Grinding Group company Walter Ewag UK, the group’s digital solutions embrace three main offerings: Production Monitor, Service Monitor and Remote Service. The first two help customers keep track of production – for example, highlighting when maintenance work is required and where/when problems may arise in production, while Remote Service helps support the help desk over a data connection.

One example of Remote Service in action concerns the machine’s back-up battery. This system maintains the power supply of a control system in the event of a power failure and it requires changing from time to time. The machine operator receives a notice on the operating panel in a timely manner, which the production manager would see on the Production Monitor. Notably, the user manual and installation instructions are available to both the operator and production manager via the Customer Cockpit, but they can also send a service request directly through the Digital Solutions app.

The service technician will be connected live via the Conference Center app and be provided with tips and hints. It is possible to send images via the whiteboard function – and the helpline technician can draw markers directly into the images.
According to the United Grinding Group there were 2500 demands for remote service during 2020.

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Q8Oils improves surface finish

Working with its client, Twilflex – a specialist in braking technologies for industrial applications, Q8Oils recently sought effective improvements to its metalworking filtration needs. While filtration methods such as paper filters provide an effective barrier against larger particles, they can allow smaller ferrous particles to pass through with the fluids, which can lead to a significant reduction in tool life expectancy.

Q8Oils regularly installs products from Eclipse Magnetics to a number of its customers’ metalworking tools as part of the company’s equipment solution services and, through partnering with expert filtration suppliers, can offer advice and support to address metalworking cleanliness issues, particularly to those with high-precision needs.

In addition to the use of its Berlioz XRS synthetic grinding fluid, Q8 installed an Eclipse Magnetics MicroMag MM20 in-line, before fluid delivery, to bolster the filtration system of Twilflix’s grinding machine. With its high-intensity magnetic core and patented fluid flow path, the MicroMag captures almost 100% of ferrous contamination from metalworking fluids. The range also boasts a compact and easy-clean design with high-capacity collection that does not block the through-flow, or impact fluid pressure or flow.

Having had the MM20 installed for one month, with intermittent usage, the filter had caught over 2 kg of ferrous materials when removed for cleaning. Q8Oils has also reported that Twilflex has seen a substantial improvement to grinding stone life, with the frequency of grinding wheel dressing largely extended. An improvement in fluid cleanliness was also noted that, in-turn, had prevented the ‘flecking’ effect caused by fine debris caught between the wheel and workpiece during the grinding process.
The MM20 will maintain its effectiveness throughout the duration of the tool’s lifespan without losing intensity. Plus, with no need to replace filters or other consumables, as well as a reduction in scrap and reject rate, the MicroMag offers fast return on investment.

A maintenance and service engineer for Twilflex said: “We tried the Eclipse magnetic filter for a month on our surface grinding machine and found it to be so effective that we decided to purchase it. We can see a difference in tool life, while coolant life is much longer. This machine doesn’t have any other filters, so we really notice the benefits.”

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Tenfold increase in tooling up-times

To date, Voestalpine Rotec GmbH, a specialist in the manufacture of precision steel pipes and tubes, has been using a manual process to place a radius on its stamping tools. Within the framework of its continuous process optimisation programme, the company recently replaced this manual operation with an automated Rösler R 4/700 SF drag-finishing system. By deploying the single-piece, dry, drag-finishing process, the usable life of the stamping tools at least doubles. For some tools, up-time can even increase by a factor of 10. For this reason, return on investment (ROI) is well below two years.

Adding edge radii to tools is an ideal application for drag-finishing technology. This mass finishing system allows the precise, targeted surface finishing of high-value, complex workpieces. Exactly defined process parameters guarantee repeatable finishing results, reports Rösler.

“From my previous occupation at a supplier of motorsport components I knew that Rösler builds such equipment,” says Hannes Winkler, assistant to the plant manager. “That’s why I contacted them first. Of course, we also contacted other suppliers of mass-finishing equipment and asked them to run processing trials.”

In the end, Voestalpine Rotec chose the R 4/700 SF system because Rösler was the only supplier that could offer a dry finishing process.

“The dry solution eliminated the water cleaning system required with the wet processing alternative,” explains Winkler. “This reduced not only the capital expenditure, but resulted in lower operating costs. Of course, the quality and long service life, as well as the high availability of the Rösler equipment, also played an important role in our decision.”

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