Challenge
Premetec embarked on a challenging mission in the steel industry segment: manufacturing tool bits from special alloy steel with an extremely high hardness rating of 58-60HRC. Historically, these tool bits were crafted through grinding to achieve their final shape, but this method presented limitations in terms of efficiency and production time. The challenge was to develop a more efficient production method that would maintain the steel’s exceptional hardness while delivering precise tool bit shapes.
Insight
Production method evolution: Premetec initiated a comprehensive exploration of production methods to optimize the manufacturing process. The goal was to replace the traditional grinding method with a more efficient alternative.
5-axis CNC machining solution: After careful evaluation, Premetec adopted a groundbreaking approach: CNC machining using a 5-axis CNC machine. This advanced technique allowed for the machining of the tool bits directly from hardened steel to their final shape.
Roughing, hardening, and finishing: The manufacturing process encompassed several key phases. First, roughing was performed to shape the tool bit. Subsequently, the tool bits underwent the critical hardening process to achieve the required 58-60HRC hardness. Finally, finishing machining ensured the precise dimensions and quality of each tool bit.
Results
Premetec’s unwavering commitment to precision and excellence yielded remarkable results:
Efficient production: The adoption of 5-axis CNC machining revolutionized the production process, eliminating the need for grinding and significantly reducing production time while maintaining quality.
Maintained hardness: Despite the shift in production methods, the tool bits consistently achieved the demanding hardness rating of 58-60HRC, a testament to the success of the hardening process.
High-precision tool bits: The tool bits manufactured using the CNC machining method exhibited precision and accuracy in their final shape, meeting the steel industry’s rigorous standards.
Cost-effective solution: The new production method not only improved efficiency but also resulted in cost savings for our client, making it a more economically viable solution.
Client satisfaction: We were able to deliver tool bits that not only met our client’s stringent requirements but also exceeded their expectations. This project strengthened the partnership between Premetec and the client, underlining our commitment to pushing the boundaries in industrial manufacturing.
In conclusion, this case study showcases Premetec’s ability to innovate and optimize production processes, even in challenging industrial segments like the steel industry.