30/01/2007
CERATIZIT solves production problem at Davy Roll
New clamping system for secure positioning and longer tool life |
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What horrifies every cutting tool engineer? When parts that are already finished have to be sent to production again to be reworked. In fact this is an unnecessary and costly working procedure. In particular, when the final product weighs up to 55 tons. But this is exactly what kept happening at Davy Roll, a British roll manufacturer. When turning and grooving rolls for steel mills, movements of the insert damaged the surface of the roll. Thanks to CERATIZIT’s commitment this problem has now been solved.
“The problem at Davy Roll was the bad positioning of the inserts“, says Klaus Kucher, mechanical segment manager at CERATIZIT UK. “Due to its unfavourable clamping and the occurring wear the insert continuously tended to tilt because of the increased cutting pressure. This caused machining problems during finishing, damaged the surface of the roll and also the tool holders. The damaged part frequently had to be welded and finish-turned.“
Optimised clamping system
For this complex production method a solution was urgently needed, as demanding repair work led to considerable delivery delays for Davy Roll. The clamping system of the tools applied until now had to be optimised. Until now the inserts were held in place by means of a top clamp. “The forces at work on such a clamp were much too high, particularly when the insert was slightly worn at the time,” says Mr Kucher.
The new solution
Together with Peter Obkircher, tooling designer at CERATIZIT UK, Klaus Kucher developed a new solution. The clamping mechanism is now situated beneath the insert. It is fixed using an eccentric shim pin and a screw. A further advantage is the technology applied and the longer tool life of the CERATIZIT insert. “The secure positioning of the insert is no longer an issue,” confirms Arthur Gallagher, tooling engineer at Davy Roll. Reworking of the rolls is now completely eliminated. “Now we are certain that every roll we machine meets our high quality criteria and that we don’t waste time on finish-turning”, says the relieved Mr Gallagher. Intensive checking of the inserts by the cutting tool engineers is also no longer necessary.
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Specials
