Hot Mill Roll Grinding Case Study Meeting Production Demands
With this Hot Mill Roll Grinding application, our Weiler Abrasives 915x102x304,8 mm Hot Pressed Wheel helped increase G-Ratio, improve material removal rate and boost their total cost savings.
The Challenge:
This customer was looking to increase their Material Removal Rate (“MRR”) on hard hard-to-grind steels in order to reduce their overall cycle time. They experienced a large increase in production and had to grind significantly more rolls to meet production demands. To avoid outsourcing some of their grinding operations and significantly increase overall costs, they began looking for ways to reduce cycle time.
The Solution:
To address this need, the Weiler Industrial Grinding Products Technology Team developed a grinding wheel, pairing a proprietary abrasive blend with advanced bond technology. This unique wheel design resulted in a wheel that was able to cut faster and last longer.
The Results:
Weiler Abrasives' Roll Grinding Technology allowed the customer to cut cycle times and, in turn, meet production demands without having to outsource a portion of their grinding operations. Utilizing the Weiler Process Solutions tool, the Weiler team was able to document best practices and identify the following improvements:
- 28% G-ratio increase
- 56% material removal rate increase
- 30% wheel life increase
- 340.200 EUR total annual cost savings:
- 79.200 EUR grinding wheel cost savings
- 261.000 EUR estimated savings productivity / overhead cost savings
