Carbide sawing of automotive forging blanks is more efficent
KASTO Ltd
Unit 3,
Flanders Industrial Park
Hedge End, Southampton
SO30 2FZ
Map
Tel. 01489 772 882
Fax. 01489 772 888
sales@kasto.uk.com
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Four new KASTO WAC 7/9 circular sawing machines employing tungsten-carbide-tipped blades from Kanefusa have replaced three high-speed-steel bandsaws and one carbide circular saw at the Midland Service Centre of Corus Engineering Steels, Wolverhampton. The firm mainly supplies steel blanks to forges serving the automotive sector, although a small proportion of output goes to machinists. Commented Operations Manager, Chris Yardy, "With induction hardening of automotive components more prevalent these days, we need to supply forges with clean, dry, swarf-free steel. This was difficult using our bandsaws, as coolant had to be directed to the point of cutting to reduce heat and prolong blade life. "In contrast, the KASTO carbide circular saws cut dry, avoiding slurry and swarf sticking to the blanks and billets, thereby ensuring that we deliver a better quality product to our customers. Absence of coolant also improves the working environment on the shop floor." Mr Yardy went on to say that circular saws cut faster than bandsaws and to better accuracy and repeatability. KASTO circular saws in particular he describes as extremely repeatable, with excellent squareness of cut, which is particularly important when producing upset forgings. Accuracy of cut length, which ranges from 10 mm to one metre, is also crucial as forges stipulate tight tolerances of typically -0 / +1 mm, or the weight equivalent. Quality control is based on measurement of first- and last-off, plus sample checking from each bin. Output from the Wolverhampton service centre is around 50,000 tonnes of steel per year, of which 85 per cent is cut to customer specification. Most jobs are for very large volumes, with some orders such as for con rod forging blanks running virtually continuously at 10,000 pieces per week. A full range of engineering steels is provided, including high carbon and high alloy varieties. Over a quarter of the total is processed through the new KASTO circular saws, up to their maximum capacity of 90 mm diameter. Larger billets to 240 mm round, 200 mm square, go onto the bandsaws, there being nine from KASTO on site. Selection of the WAC 7/9 machines rather than those offered by two other shortlisted circular saw suppliers hinged on KASTO's ability to offer fully integrated sawing cells with 5-tonne, 9-metre capacity bundle loader. Other companies were offering add-on loaders of another make to feed the saw. In addition, since it started supplying Corus in the early 90s, KASTO's service and spares availability have been reliable.
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