Success Storie thin-layer technology

Flagship project: thin-layer technology

How a cooperation leads to fast and efficient sawing at Ø 130 - 300 mm

Time is one of the most important resources for companies. Many good reasons to focus on the ‘thin-layer technology’ for the machine construction sector - starting with the cost-per-cut, reduction of the cutting time, additional sawing capacity through to material savings and/or more sawing sections from the material.

Customer profile

Günther + Schramm is the leading system service provider for steel, stainless steel and aluminium in southern Germany. The company was founded in 1930 and has a workforce of around 180 at four sites in Oberkochen, Königsbronn, Stuttgart and Mannheim. This steel trader and system service provider works in the classic metal trading industry, and also offers various tool manufacturing services, as well as realising complex outsourcing projects in the material and process logistics field.

Machine partner

The company MEBA Metall- Bandsägemaschinen GmbH is a metal band saw blade specialist based in Westerheim in Baden-Württemberg and is one of the leading manufacturers in the world. This family company, which was founded in 1958, supplies standardised single saws and customised complete solutions with material handling and length measuring systems in all automation levels.

Challenges and requirements

Time is one of the most important resources for companies. Productive, efficient and economic sawing pays off: both for steel traders that process orders with large lot sizes, and also for forge workshops that need to saw shorter sections but in higher quantities. Many good reasons to focus on the ‘thin-layer technol-ogy’ for the machine construction sector - starting with the cost-per-cut, reduction of the cutting time, addi-tional sawing capacity through to material savings and/or more sawing sections from the material.

The goal was to test a new band saw blade for Günther + Schramm that could meet the specifications of the thin-layer technology. This system service provider was not able to reach the specified machining rate for a heat-treatable steel with a diameter of 200 mm using its own sawing machine. The company wanted to find a manufacturer that could supply a suitable machine for testing purposes. This paved the way for a joint pro-ject that also included MEBA. A further advantage here was the proximity to the site that guaranteed short paths and fast intervention into the process during the test phase.

The solution

HIGHER CUTTING RATES THANKS TO HIGHER TORQUES AND BAND SAW BLADE INNOVATION

The steel trader Günther + Schramm tested a machine-band saw blade combination of MEBA and WIKUS that would allow them to cut heat-treatable steel with a diameter of 200 mm and also enter the thin-layer technology field. To carry out the cutting tests with the band saw blade ARION® FG on a MEBA standard machine, MEBA first adapted the guide elements and optimised the chip brushes and the coolant supply, after which a cutting rate of 440 cm²/min was reached. The thin-layer belt was also able to reduce the costs per cut at Günther + Schramm by 40%. The project partners also saw additional potential for raising the cut-ting speed of the band saw blade machine, which is why MEBA provided a solution with the required power. This meant that the machine was now twice as fast as every other standard machine on the market.

The stipulated cutting rates can be reached in combination with the band saw blade ARION® FG thanks to its carbide blade with a highly wear-resistant carbide coating. The special WIKUS thin-layer technology with extremely high blade stability also ensures the precise evenness of the cutting surface. For further optimisa-tion, WIKUS developed a special tooth geometry, calculated cutting parameters and also monitored all cut-ting test series. During the project phase, it was possible to save costs of approx. 20 % depending on the material being cut.

Achieving success in the market thanks to cooperation projects

During the scope of the cooperation, we were able to achieve very high cutting rates with the band saw blade ARION® FG and our new, optimised band saw blade machine. This is unique in the market at this time. The thin-layer technology now allows us to achieve approx. 20 - 35 m² depending on the material dis-tribution when sawing construction steel, heat-treated steel, and rust and acid-resistant steel with diameters of between 40 - 280 mm. At the same time, the belt-machine combination leads to extremely highly quality and precise results.

Thin-layer technology for high cutting rates

Thanks to the thin-layer technology, we are now able to saw heat-treatable steel with a diameter of 200 millimetres almost four times as quickly as with conventional bimetal band saw blades. The matching band saw blade alone was able to improve the machining performance significantly; this was further improved with a matching machine. The unique fact or here, for us and our customers, is that it is now possible to also realise urgent orders of a few hundred cuts very quickly.

WIKUS Kundenservice

Extensive support & test cuts on site

During two years of successful test series more than 28,000 cuts and an area of approx. 500m² were machined.

Development aligned to customer requirements

WIKUS supplied newly developed teeth geometries for the innovative machine-belt combination.

Cooperation project thin-layer technology

Interdisciplinary cooperation team with a machine and tool manufacturer, and users bundles competencies.

Reduction of overall costs thanks to machine optimisation

Calculation of the cutting costs (cost-per-cut) and material savings thanks to smaller cutting width.

Any more questions?

Our experts in the WIKUS application engineering division will be happy to help you answer further technical questions connected to band selection and use.

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