FOUNDRIES AND FINISHING SERVICES:
Metalcasting is on the move. The industry bounced back hard from the recession with estimated growth expanding from $25.46 billion in 2010 to a 2015 forecast of $37.5 billion, according to the Metalcasting Forecast and Trends Report, published by the American Foundry Society. While growth in orders from existing customers only goes so far, foundries are discovering that they can grow laterally by expanding their existing service offerings. One of the new popular offerings is finishing services that bring materials closer to a final finish than was previously available from foundries.
Since foundries typically have lower labor expenses than manufacturers, they can provide grinding and finishing services more affordably than what most manufacturer can leverage internally. This makes finishing a very attractive value-add service to entice new business and grow revenue from existing customers, and foundries can easily offer rough to mid-range finishing services for cast or forged parts.
WHAT TO LOOK FOR IN ABRASIVE WHEELS:
Foundries wishing to offer finishing services need to take care to select the right wheel to achieve optimal results and should start by thinking about balance. You need a wheel that features a high material removal rate, yet leaves a finish that is much less rough than other wheels with similar removal capabilities. Rex-Cut Sigma Green and Sigma Green Max grinding wheels are solid options for foundry applications for this very reason. Sigma Green wheels are produced from bonded resin with a unique combination of grains that enables the wheel to grind extremely fast compared to other products, yet maintain a better finish. Sigma Green wheels are also more durable, lowering abrasive replacement cost. And with a more consistent finish, overall finishing time is reduced, driving down labor costs and overall production time.
Another consideration is the wheel’s performance on aluminum. With a long-term growth rate of 4.4%, according to the same forecast and trends report, aluminum demand is rising due to production increases from manufacturing sectors such as the automotive industry. Any abrasive wheel you select must work well on aluminum services to satisfy this demand, and the Sigma Green Wheel features robust capability on aluminum surfaces.
WHEEL SAFETY:
The Sigma Green Wheel is also extremely well-balanced, does not chatter and causes much less stress on the operator when using the wheel for an extended duration. Vibration is a primary concern, as it can cause Hand/Arm Vibration Syndrome. This serious neurological and circulatory condition is identified by numbness and pain in the fingers, with the fingers actually changing color in severe circumstances. The condition is serious enough that the European Union has started regulating wheel usage and the Occupational Health and Safety Administration (OSHA) is now looking at mitigating Hand/Arm Vibration Syndrome in the U.S. Taking proactive steps to minimize exposure to vibration saves on direct labor costs and shields against workers comp claims, reduced production, and even litigation.
FINE FINISHING:
Beyond Sigma Green, Rex-Cut offers a wide range of wheels to deliver even finer finishes, for foundries that want to expand their service offerings further. Non-woven cotton fiber and other premium abrasive products are available for a variety of grinding, deburring, blending, and finishing applications that serve a diverse range of applications. Rex-Cut offers a variety of wheels that provide great pathways for foundries to open and explore new revenue channels with minimal expansion of their core operations.
SIGMA GREEN:
Looking for more information on Sigma Green grinding wheels? Visit our product page here.
To watch how quickly Sigma Green grinds Stainless Steel, watch our 30 second demo video here.
