[Case Study] Extension of Lifespan through PCD Technology (High Hardness Components Business)
Significantly reduce setup time due to parts deterioration! We provide support from current situation analysis and issue identification to solution proposals, parts supply, and effectiveness measurement.
【Performance Introduction】 ○Part Name: Centerless Blade ○Device Name: Centerless Grinding Machine ○Application: Used for processed products (sintered PCD / φ0.8×21L) at our company ■Introduction (From the Field) We received a consultation from our manufacturing department regarding measures to improve equipment utilization rates in the bottleneck process and reduce setup changeover times. ■Current Situation Analysis In the relevant process, a carbide blade was used on the centerless grinding machine, resulting in a setup changeover task occurring once a day for one hour due to wear. Additionally, the worn parts were being discarded. ■Issue Identification and Proposal To reduce the setup changeover time for blade replacement, we proposed a PCD blade with high wear resistance. While other companies were unable to produce PCD blades with a thickness of less than 1mm without warping, our high-hardness component business achieved a quality that does not warp. ■Implementation and Effects The setup changeover task that occurred once a day was reduced to once every ten days. We achieved a reduction of 18 hours in labor and 18 discarded blades over the course of a month!
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basic information
PR Points: ★ Strong connections with brazing technology and wedge bonding ★ Processing technology that does not warp even at thicknesses below 0.3mm ★ Increased operating rate and reduced setup changeover time ★ Applicable to wear parts such as guides and positioning
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Applications/Examples of results
【Case Studies of Problem Discovery and Resolution】 ■Case 1 (Major Precision Parts Manufacturer) In response to quality deterioration due to the aging of cutting edges in the precision parts cutting process, we conducted a root cause analysis of the quality decline and created an improvement proposal report, which was implemented. This led to an enhancement and stabilization of the quality of the customer's products, achieving optimization of the customer's production process. ■Case 2 (Major Parts Processing Manufacturer) For customers using carbide material mold punch parts, we proposed PCD material parts and improved processing methods. This resulted in achieving a continuous production quantity more than ten times that of before the proposal! We stabilized product quality and significantly reduced the time for regrinding and setup changeover tasks. ■Case 3 (Equipment Manufacturer) For expensive unit parts that were being used as disposable within equipment parts, we leveraged our proposal capabilities and processing technology to suggest a partially replaceable design. This simplified the replacement process and reduced part costs, contributing to increased production numbers and reduced manufacturing costs.
Detailed information
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Grinding is performed by cutting into the high-speed rotating grinding wheel (grinding wheel) while maintaining the positional relationship between the workpiece, the centerless blade (support blade), and the adjusting stone (adjusting wheel).
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Samsung Diamond Industrial is a manufacturer of processing equipment that provides optimal process conditions using original cutting edges and laser oscillators for processing methods such as scribing, breaking, drilling, and patterning, along with automated devices that achieve high productivity. Since its establishment in 1935, the company has utilized its "high-quality cutting technology for various types of glass" to offer processing processes, equipment, and tools that can handle "all kinds of hard and brittle materials, as well as multilayer structures that include metals and organic materials." With solutions backed by theory and proven results, we aim to be a reliable "one-and-only partner" for our customers. Please feel free to contact us.