May 2010 / Volume 62 / Issue 5|
Enabling product line expansion
By CTE Staff
After more than 45 years in business, The M.K. Morse Co. is a stalwart presence in the field of manufacturing saw blades and power tool accessories. While serving the industrial, construction and welding markets, the Canton, Ohio, firm has introduced a range of sawing products, including bimetal and carbon bandsaw blades and specially engineered carbide-tipped blades.
With every new addition to its product line and services, M.K. Morse has had to negotiate new challenges and find new ways of doing things. One recent example is the company’s introduction of its Revolution thin-kerf, 360mm cermet-tipped saw blade for high-volume cutting of ferrous and nonferrous metals.
Courtesy of Transor Filter USA
Compared to the company’s other circular and bandsaw blades, the cermet-tipped products are more intricate and demand greater accuracy, said Ed Galosi, product engineering manager for M.K. Morse. “If you’re talking about a carbide-tipped blade for wood, the tolerances can be easily in the thousandths of an inch, maybe even up to 0.010 ". In a metalcutting, carbide-tipped blade, maybe 0.004 " or 0.006 "; but as we move into cermets, the tolerances could be 0.002 " or less in all dimensions.”
For the production equipment to make the cermet blades, M.K. Morse partnered with grinding machine builder Vollmer of American Corp., Carnegie, Pa. M.K. Morse produces the cermet-tip blades in cells consisting of various configurations of a Vollmer CHD270, which grinds tooth tops and faces; a CHF270, for grinding sides; and a ND270 robotic unit, which enables unattended loading.
Considering the demands of the application, Vollmer representatives emphasized the need for optimal coolant filtration and suggested that all the machines be connected to a Transor filter system, which is capable of filtering particles in coolant to 1μm.
“Coolant cleanliness if often overlooked, but is very important in grinding hard materials, such as carbide and cermet,” Galosi said. Dirty coolant, he added, interferes with the grinding wheels’ cutting and can lead to poor surface finish and overheating of the carbide or cermet tip, which can cause microcracking of the tip and premature tool failure.
Quality coolant filtration is also essential to hold tight tolerances. “When you’re not cutting the cermet (due to the presence of dirt and debris), you’re pushing and rubbing it and that, in turn, causes the blade to deflect and the tolerance won’t hold up to what you want,” Galosi said.
A chiller to monitor and maintain a consistent temperature ensures thermal stability.
In addition to incorporating a chiller to monitor and maintain a consistent temperature, the Transor system is also capable of self-cleaning. Irv Kaage, president of the Elk Grove Village, Ill.-based Transor Filter USA, explained: “Obviously, the finer you go in terms of filtration—as in the case of filtering to 1μm vs. 10μm—the more frequently you have to replace the filter cartridge. But the Transor system incorporates a feature called edge filtration. Instead of having to replace the filter elements, edge filtration cleans them automatically with compressed air every 8 hours.” Thus downtime for changing filter cartridges is eliminated.
And along with the dirt and debris disposal, the Transor system removes carbide from the elements and places them into a cloth bag, according to Kaage. “As there is no filter media contained in the sludge, the resale value of the carbide is higher than other forms of filtration,” he said.
Looking back to the start of the cermet-tipped blade production and how Transor Filter helped his company achieve its goals, Galosi added, “We didn’t want to cut corners on filtration for the sake of sparing a couple of dollars, so we went ahead with [Vollmer’s] recommendation. And it’s proven to be a good choice.” CTE
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