54 ■ ■ ■ Case Study
Easing the grind
of cost reduction
Automotive supplier finds success with
new disks for flash removal, deburring
The squeeze on companies in
automotive supply chains
to reduce their manufacturing costs is powerful. That
means no stone is left unturned in
search of cost savings.
SPX CONTECH® is one such
automotive supplier. This producer of
one-piece rack-and-pinion housings
for Tier 1 companies is continuously
looking for methods, processes, and
products to reduce costs in an increasingly competitive marketplace. Even
the smallest improvements can make
big differences, especially considering
the company’s 110,000-square-foot
Auburn, Ind., facility produces 4. 5
million die-cast housings per year and
ships more than 19 million pounds of
aluminum annually.
BAutomotive parts supplier SPX CONTECH had struggled with quick-attach abrasive fiber disks for its flash removal and deburring of its die-cast aluminum parts. The
company found a replacement disk that lasts three times longer than the problem disks.
In early 2005 SPX CONTECH
decided to evaluate the abrasive disks
used in its 22 die-casting cells. The
abrasive disks are used to remove flash
and deburr die-cast parts before they
are shipped to customers.
By the end of that year, company
officials had found that this small
change led to improved productivity
and cost savings because the disks
lasted longer than the ones used previously.
Flash: Opportunity
for Improvement
SPX CONTECH had been using
quick-attach abrasive fiber disks for its
flash removal and deburring processes.
The disks, however, sometimes were
cupping—no longer remaining flat—
as a result of changes in moisture content. In some cases, the fiber disks
would detach from the button.
The company approached 3M for
help finding a disk that could tackle
tough burrs without being too aggressive on the part finish, while also providing a surface finish that met customer specifications. It was important
not to add production steps or
increase costs with the answer.
More specifically, SPX CONTECH was looking for 3-inch abrasive
disks for its flash removal and deburring processes that used right-angle
die grinders to finish 2-foot by 3-in.-
dia. aluminum die-cast parts. The
disks had to hold up against the pressures associated with a high-volume
manufacturing operation.
The company also wanted to see if
the abrasive disks might eliminate
excessive loading on the die-cast
parts. Abrasive minerals that dull during grinding can cause premature
loading because operators working
with such less-than-optimal disks can
apply excessive pressure while grinding. A mineral that retains its sharpness, theoretically, will cut faster and
avoid the need to have operators
apply excessive pressure.
An abrasive disk that would allow
operators to work in difficult areas,
such as corners, was another requirement. An abrasive with a backing
that was flexible, yet stronger than a
typical fiber or cloth backing, was a
suitable choice.
No Stranger to
New Technology
SPX CONTECH is a company that
prides itself on embracing new
technology.
“We’re always on the lookout
for the latest technologies that will
help us provide competitive cost
and quality to customers,” said
Mike Schieber, director of operations for the company’s Auburn,
Ind., facility.
P2000™ aluminum casting is
one example. SPX CONTECH
developed this proprietary die-casting process to create stronger
aluminum components with the
same efficiency it did using traditional high-pressure die casting
(HPDC) to create parts. P2000
combines the advantages of
HPDC—the abilities to achieve
near net shape, deliver fast cycle
times, and to work with a variety
of alloys—with low-pressure casting, which produces die-cast parts
that have minimal porosity, are
solution heat-treatable, and have
thick wall sections.
Currently the company is targeting axle, steering, and suspension system components for its
aluminum casting technology.
Going With the Grain
and a New Disk
SPX CONTECH historically used
abrasives made with ceramic minerals.
That led them to select 3M’s
Cubitron™ abrasive grain.
This abrasive grain is a proprietary
ceramic aluminum oxide mineral that
is designed to cut through metal
quickly. As each abrasive grain fractures during usage, a fresh, sharp surface is exposed until the disk reaches
the end of its useful life.
After evaluating several quick-release fiber disks through extensive
testing, SPX CONTECH began using
the 3M™ Roloc™ Disc 988R in
November 2005. This quick-attach
abrasive disk, which contains the
Cubitron abrasive grain, is designed
for weld removal, weld leveling, and
deburring.
The FABRICATOR | An FMA Publication
www.thefabricator.com | March 2007
