Producing parts at high volumes often means that minor process improvements can dramatically impact the cost of production. Often, a single change in technology utilization can yield results that have a sizable impact on a part’s profitability. Likewise, slowdowns and bottlenecks in production can be costly.

At cutting tool manufacturer Ceratizit, the problem was unusual: Its wire EDMs kept catching on fire.

Ceratizit is a cutting tool manufacturer that focuses on high-end tooling for the metalworking industry. Ceratizit USA, the United States branch of the company, is headquartered in Schaumberg, Illinois, where it produces both standard and custom tooling for shops working in the automotive and aerospace industries, among others.

The company’s tooling offerings include polycrystalline diamond (PCD) cutting tools. PCD’s extreme hardness and wear resistance make it an excellent choice for cutting tools, as it can outlast solid carbide tools by 10 times or more, according to the company. However, its desirable qualities also make it a challenge to cut into shape, which is one reason why the company relies on wire EDMs for producing PCD cutting tools.

Unfortunately, the wire EDM production line for PCD tooling, which includes five machines and is intended to run 24 hours a day was plagued by disruptions.

According to the company, the EDM department was a high consumer of cutting fluid, specifically the dielectric oil used for the wire EDM process. “Oil loss from evaporation and dragout — oil clinging to parts as they’re removed from the machine — dramatically impacted our oil consumption,” Facilities and Maintenance Manager Manfred Haemmerle says.

Additionally, the filters needed changing two to three times a year. “When you do a filter change, more product is also taken out of the machine and fresh product must be installed,” Haemmerle explains. “It’s the labor, too. Changing filters is not a half-hour job; it’s a half-day job.” Altogether, these drains on the oil supply forced the company to go through four to five drums of oil every year.

While these oil-consumption woes were concerning, the physical qualities of the dielectric oil caused an additional problem. The oil had a relatively low flash point — the temperature at which a material ignites — which led to repeated fires in the machines as they cut the PCD.

“We were experiencing at least two fires per machine every year,” says Haemmerle. “That is in addition to numerous flare-ups that quickly died out.” Each EDM is equipped with a fire-suppression system that floods the work area with carbon dioxide the moment it detects a fire. At no point were the workers RPEW Insert in danger, nor were the machines at risk of being permanently damaged. But the fires (and even the small flare-ups) would still damage the machines.

The need to replace damaged machine components led to days of downtime every year. On top of that, the company needed to replace the CO2 cannister that doused the fire before an EDM could boot up. “We will not start a machine unless it is totally safe to do so,” Haemmerle says. Eventually, the company began keeping multiple cannisters of CO2 in stock to avoid last-minute replacements that would cause further downtime.

Essentially, the company was planning around the expectation that its EDM oil would occasionally flare up, and that was costing it in material losses, machine component replacements and machine downtime. Looking for APMT Insert a more manageable process, Ceratizit reached out to Blaser Swisslube for a solution.

After consultation with Blaser and their local distributor DXP Enterprises, Ceratizit decided to try out a new dielectric oil, the Blasospark GT250. DXP Oil and Coolant Specialist Andy Anderson convinced the company to try the new fluid, which is a synthetic paraffin oil converted from natural gas, eliminating impurities that can contaminate products derived from crude oil.

The biggest draw of the new oil is its higher flash point, igniting at 230° F, roughly twice the temperature of the previous product’s flash point. Since adopting this oil, the company has yet to have a single fire in its wire EDM line, allowing it to scale back its stock of CO2 cannisters and eliminating costly downtime.

Additionally, the replacement oil is less prone to both evaporation and dragout, and the filters need changing only once every year. “With our previous product, we were going through four to five barrels every year,” Haemmerle says. “With the Blaser oil, it’s only one barrel a year.”

With one process change, the company has dramatically reduced maintenance time, oil consumption and machine replacement parts. Ceratizit is now running its wire EDM line much closer to its 24-hour goal, improving its production of PCD cutting tools. 

It is not often that you fight fire with oil.

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Carbide milling inserts are cutting tools made from a hard and durable material known as carbide. These inserts are used in milling SNGX Insert machines and are designed to remove material from a workpiece by rotating a cutting tool that contains one or more inserts.

The carbide milling inserts have several advantages over other types of cutting tools. They are highly resistant to wear and can withstand high temperatures, which makes them ideal for cutting through hard materials such as steel and cast iron. They also have a long lifespan and require minimal maintenance, which can save time and money in the long run.

There are several different types of carbide milling inserts, each designed for specific milling applications. Some common types include square, round, and triangular inserts, each with unique cutting geometries that offer different benefits in terms of cutting speed, accuracy, and surface finish.

Carbide milling inserts can be purchased from a variety of manufacturers and suppliers, and they are available in a wide range Carbide Grooving Inserts of sizes, shapes, and grades to suit different milling requirements. When selecting carbide milling inserts, it's important to consider factors such as the workpiece material, cutting conditions, and desired surface finish to ensure the best possible performance and results.

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As a strategic metal, Carbide Inserts tungsten is widely used in metallurgical machinery, petroleum chemistry, aerial and space industries and national defence engineering. So, today we are going to talk about tungsten supply and demand.

China has rich tungsten resources. During the past 10 years, China supplys more tungsten than the demand. By the end of 1998, China’s tungsten production capacity exceeded 35,000 tons. In recent years, the global demand for tungsten has been about 31,000 tons, whild China’s tungsten production in 1998 amounted to about 22,000 tons, making up 71% of the global tungsten demand.

At present, China’s domestic tungsten demand is about 8,000 tons and most of its tungsten is exported. While, excess tungsten exports have caused a decline in the global tungsten price, which is unfavorable to the development of China’s tungsten industry.
Varied international and domestic tungsten markets make it difficult to accurately predict the future demand for tungsten.
It is necessary to maintain and give full play to tungsten superiority tungsten carbide inserts to guarantee a sustainable development of China’s tungsten industry.
Above is about tungsten supply and demand.

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Sometimes you have to watch between the lines to understand how much authority governmental agencies really have. The Bureau of Alcohol, Tobacco, Firearms and Explosives is a case in point. The issue is what ammunition the ATF considers to be "armor piercing ammunition" and not ammunition used for "sporting purposes."

In early Deep Hole Drilling Inserts December meetings, the ATF met with gun control activist groups, the NRA, firearms industry groups and others. The ATF expressed opinions that "warrant particular scrutiny," NRA representatives, who attended those meetings, noted on the group's website.

Under a law adopted in 1986, the definition of "armor piercing ammunition" is "a projectile or projectile core which may be used in a handgun and which is constructed entirely (excluding the presence of traces of other substances) from one or a combination of tungsten alloys, steel, iron, brass, beryllium copper or depleted uranium."

The intent of the law, which is good, is to protect law enforcement officers from ammunition that could penetrate soft body armor.

The challenge is that there are handguns designed to fire certain rifle calibers and that rifle ammunition wasn't designed for anything other than sporting purposes. That means you could have a rifle caliber ammunition type outlawed on the basis that it can be fired in a handgun and pierce armor. That covers a wide range of rifle ammunition that could be outlawed under a stricter interpretation of this law.

According to the NRA representatives who attended the meetings, the ATF "suggested that it believes that the armor piercing ammunition law was intended to affect all Cast Iron Inserts ammunition capable of penetrating soft body armor worn by law enforcement officers."

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At first, the comparison between fluorescent and tungsten may seem simple, but such a decision can impact the work environment, home environment, product quality, even financial situation. When comparing fluorescent and tungsten lighting, important factors to consider include location, spacing, safety and cost.

Instructions

1
Consider the location and purpose of the light in question. Is it a smaller room or a large, open area? Will people be reading and studying under the light or moving actively? If a work-based environment, is the location a photo studio or a place that works with details and colors? Does the light require a dimmer?

2
Consider the output and safety of the light. Fluorescent light bulbs emit 90 to 95 percent of their energy as light, while tungsten light bulbs emit 90 to 95 percent of their energy as heat. Will the lights be used in wide, open spaces? Will the lights be near flammable materials or papers? Are the lights recessed and potentially prone to overheating?

3
Consider cost and energy efficiency. Fluorescent lights will always be more energy efficient than tungsten, however, there may be a cost involved to make a fixture fluorescent-friendly. Additionally, take note of how long the light and location will be in use; the long-term operating cost of fluorescent lights is less than that of tungsten, but in the short term tungsten may be less expensive.

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Tips & Warnings
If cost is a major factor, crunch some numbers to figure out which light is more financially feasible. For instance, if you are renting a small office for five years, using fluorescent lighting may be more cost effective. If you rent the same small office for one year, on the other hand, tungsten may work better. Remember to include the cost of any fixtures as well as modifications necessary to accommodate those fixtures.

If the decision comes down to the issue of safety, choose fluorescent. With a significantly lower operating temperature, fluorescent lights are far less likely to cause burns or fires if the fixture is knocked over as well as less likely to overheat when used in smaller, contained spaces.

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Cermet Inserts Tel.: 86 592 5129696; Fax: 86 592 5129797
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