Troubleshooting Grinding Wheel Issues for a Machine Manufacturer

Before Eagle

Prior to contacting Eagle Superabrasives, Seth was using a multi-step grinding process using aluminum oxide wheels. He described the old process as:

• Time-consuming
• Often producing inconsistent results
• Generating an excess amount of heat, degrading the quality and sharpness of the blades being produced
• He also mentioned wheel breakage causing him to Frequently run out of wheel

Our Solutions

The initial conversation addressed each issue individually, allowing us to work with Seth to find the right solution for them. The results included:

• Creating a magnetic spindle and wheel mount, allowing for a quick wheel change from the roughing to finishing stages
• Utilizing CBN abrasive, along with an electroplated bond to reduce heat generation during sharpening, eliminating cool-down periods
• To ensure we could meet their needs, Eagle created a stocking program for this client’s wheels, allowing for same-day shipping.

The Benefits

Reduced Downtime Due to Overheating and Wheel Changes

Previous wheels would overheat, causing the need for frequent wheel changes.

“Eagle’s wheels never overheat, with surface temperatures rarely exceeding 90 degrees. When we need to change to our finish grit, the magnetic core makes doing so quick and efficient. We’ve been able to reduce our cycle time from 15 minutes to just under one minute due to faster wheel changes.”

Increased Repeatability

“Ease of operation and repeatability are very important to us, both were greatly increased since using Eagle’s CBN wheels.”, said Seth.

Consistently High Quality

Seth described Eagle’s consistency in delivering quality wheels as “unmatched”, and the switch as a “total game changer”.

Outstanding Customer Service

Eagle’s Make and Hold program eliminated delays due to long lead times by creating a simple stocking solution. Now, Seth’s wheels are always ready to ship the same day.

Measured Results

Let’s break down how reducing cycle time from 15 minutes to 45 seconds creates a return on your investment, and ultimately saves you money.

The total cost of running a machine depends on the machine cost, plus the labor cost, maintenance cost, and utility cost divided by the number of operating hours.

Consider an average industrial machine, which costs $50,000 at purchase (in this example, we will be neglecting depreciation). If labor costs $20/hour, maintenance averages $2.50/hour, and utilities clock in around $5/hour, with a running time of 2,000 hours, the total cost per hour to run your machine equals $77.50.

Using the client’s previous cycle time of 15 minutes, the average sharpening cycle costs $19.38. 

After switching to Eagle’s CBN wheels, the client reported achieving 45-second cycle times. This reduction lowers the cost of a sharpening cycle to just
97 cents.

With the cycle time and changeover being so much faster the operator and machine is able to sharpen many more blades or cutters in a day, thus increasing profits by a large amount.

What Sets Us Apart

Among the noticeable differences in product quality, the increase in productivity, and the heightened levels of achievement experienced by our client after choosing Eagle, one of the biggest differences described is our customer service. Eagle prides itself on being a no-hassle supplier, where experienced representatives are always available to help clients in need.

Our featured client describes a custom wheel experience with us,
“After working through the specifics, we had a physical product ready for testing in just under a month, from conversation to receiving our wheels.”

Our track record speaks for itself. Join Seth, along with many other manufacturers, and switch to a wheel supplier whose service and customization abilities ensure maximum return on investment.