Success Story Aluminium Foundry

SAW PACKAGE FOR THE ALUMINIUM FOUNDRY

Test cuts verify best sawing results compared to the competition

Based on extensive cutting tests on site and targeted efficiency measures, a made-to-measure sawing package was developed for Aluenge that makes today’s sawing process economic.

Customer profile

Since 2000, Aluenge Indústria e Comércio de Alumínio has been developing and manufacturing systems for melting, casting and heat treating aluminium and alloys of the series 5000, 6000 and 7000 in South America. Over time the activities connected to the technological development of processes and products for different industrial segments have grown.

Challenges and requirements

Aluenge uses various cutting methods in the production line. Carbide band saw blades are used to process aluminium blocks on the horizontal band saw blade machine; in contrast, aluminium rods are used with bimetal band saw blades on the vertical machine. In addition to the selection of matching band saw blades and cutting parameters, the aim is to identify and highlight economic efficiency potential in the sawing process.

The solution

ECONOMIC SAWING PACKAGE FOR MAXIMUM EFFICIENCY

Minimum downtime is a central factor for cost efficiency in sawing operations. The versatile band saw blades made of bimetal or carbide, that do not need to be replaced as often, play an important role here. For example, the bimetal band saw blades, such as SKALAR^® X3000^® and SELEKTA^® GS X3000^® by WIKUS, offer excellent wear-resistance in conventional applications combined with short cutting times. Carbide band saw blades are ideal for very high cutting outputs and improved machine productivity: for instance, the band saw blade for non-ferrous metal foundries ECUDOR^® and FUTURA^® NE for non-ferrous metals.
Based on extensive cutting tests on site and targeted efficiency measures, a made-to-measure sawing package was developed for Aluenge that makes today’s sawing process economic.

A comparison of band saw blades

We have tested almost every band saw blade available on the market from every manufacturer. We achieved the best sawing results using WIKUS products. For instance, we have been able to extend the service life by 59% compared to a former supplier, which in turn saves a significant amount of costs.