Cost Justification for Tungsten Carbide Rolls vs. Split & Bolted
From the first day that I started working at Ameristar Fence, I knew I had to keep track of wear and tear of our tooling in our facility as I had done in the past at Wheatland Tube, after a period of time I set our tolerances at 2,000 tons of maximum production on 1.315 and 1.660 O.D. tooling, and at 3,000 tons on larger tooling sets 1.900 to 2.875, which happened to be pretty much the same as my past experience at Wheatland Tube…after a period of time the topic of carbide tooling was brought up during a meeting in which I stated that in my past experience with my former employer it had given us great results with longer production time and less reworks, saving rework and shipping costs; after our meeting I assured my boss that it would serve us greatly with production and cost saving measures, so I was given the green light to “try” a set of carbide tooling…after this “trial” I am very happy to share our results with the tubing industry…after acquisition of a 1.660 tooling set in August 2006, which still has not been reworked as of May of 2008, the output of this particular tooling set has reached 9,256 tons (an increase of more than 300% in production) with no sizing problems as of yet and very minimal or no roll marks during production as well, while at the same time keeping galv build up to a minimum or none whatsoever in some cases, therefore making it safer for our operators by keeping their hands out of harms way by removing build up during production (on tooling)...after the success of our trial with 1.660 tooling I was given the green light to order a 2.017 sq. tooling set, maximum production on D-2 steel was set at 500 to 600 tons, after we started production with our carbide tooling, our first rework took part after 3147 tons on that particular tooling set, which if you do the math, well, the results pretty much speak for themselves; as impressive as these results were, the biggest savings we made were with our acquisition of our .590 Sq. carbide tooling set, we had been producing tube with split and bolted D-2 steel tooling which had to be reworked after 3.5 to 4 million feet, after production with carbide inserted tooling took place, our first rework of our carbide tooling took place after 53,000,000 feet, this alone saved us 13 reworks which would have been done with D-2 steel tooling, so, after seeing the results we get out of D-2 steel vs. Carbide inserted tooling, the decision was simple to slowly move over to carbide as tooling sets’ lifespan wears out, our inventory now includes 6 sets of carbide inserted tooling with 2 more due in house within 3 months, as good a result as D-2 steel has given us, carbide inserted tooling by far has the best results bar none.
Tool Room Tech.
Ameristar Fence Products.
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