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How to Increase Material Removal Efficiency and Your

Bottom Line
www.fabricatingandmetalworking.com/2018/01/how-to-increase-material-removal-efficiency-and-your-bottom-line/

By Lucas Bryk

From foundries to fabrication shops and final finishing, all
areas of metalworking are looking to increase profitability
through process efficiencies. Pneumatic tools that are
appropriate for material removal can enable users to improve
their productivity significantly. Here is a review of the latest air
tools and how they are best suited to particular applications,
along with considerations to take when specifying tools.

For larger removal areas, angle grinders are ideal tools to use with 4 in, 5 in, 7 in and 9 in
abrasive wheels, Type 1 or Type 27, as well as flap wheels or sanding pads. Look for
powerful pneumatic angle grinders that offer 2.8 hp in both 7 in and 9 in abrasive wheel
capacities and are capable of 2,000 hours of continuous service before maintenance. (first
view)

For larger removal areas, angle grinders are ideal tools to use with 4 in, 5 in, 7 in and 9 in
abrasive wheels, Type 1 or Type 27, as well as flap wheels or sanding pads. Look for
powerful pneumatic angle grinders that offer 2.8 hp in both 7 in and 9 in abrasive wheel
capacities and are capable of 2,000 hours of continuous service before maintenance.
(second view)

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7 m/s² on a pistol needle scaler to limit operator exposure.For difficult-to-reach areas.7 hp with speeds from 15. chipping hammers and scalers are the ideal tools for the job. It is important to find a tool with low vibration to ensure safety and reduce the risk of worker injury. 2/5 .4 hp and 0. more refined fettling. Look for models that are built to withstand 1. Some can achieve levels of vibrations as low as 1. Look for chipping hammers that provide low vibration through insulated grips and a unique air cushion vibration damping system while providing substantial power in order to remove stubborn materials and coatings. and offer between 0.000 working hours before maintenance is required. or work inside casts and molds where angle grinders are too large.000 rpm to 30. They can also be fitted with sanding pads and polishing flap wheels for finishing purposes. To remove the build-up of unwanted burrs or raised edges on larger surface areas and to remove thicker materials.000 rpm to cover all material removal applications. lightweight and ergonomic die grinders used with carbide burrs and mounted points are more suitable.

4 hp and 0. For larger removal areas.000 hours of continuous service before maintenance. chipping hammers are necessary to achieve the desired result. risers and burrs left behind by the casting process must be removed. Type 1 or Type 27. and offer between 0. Tools that can withstand the harsh environments and rigors of the job and are reliable and durable will get the job done more quickly and efficiently. belt sanders are ideal for the job thanks to 3/5 . For polishing and finishing. Typically used for more refined fettling and work inside casts and molds. sprues. die grinders can also be fitted with sanding pads and polishing flap wheels for finishing purposes. Angle and die grinders are the principle tools for this fettling process and their use varies depending on the amount of material that must be removed. are used to both clean weld seals and finish components that have been forged. sanders are ideal for helping adjust the final shape of the product and also returning a worn product back to its original sheen. 7 in and 9 in abrasive wheels.7 hp with speeds from 15. 5 in. HAV can have negative effects on the body if using tools for a long time.000 rpm to 30. and because of this. Owing to the vibrations that are given off by chipping hammers. the cores. In addition to carbide burrs used for fettling. paint and other coatings. Suitable for surface clean-up jobs. as well as flap wheels or sanding pads. Some can achieve levels of vibrations as low as 1. needle scalers provide a series of percussive needles designed to easily lift off rust. it is important to find a tool with low vibration to ensure safety and reduce the risk of worker injury. runners. ergonomic die grinders provide users with greater control and maneuverability.000 working hours before maintenance is required. For areas requiring precise sanding as well as an abrasive surface. MATERIAL REMOVAL IN FABRICATION Angle and die grinders. it is important to have the right tool for the job. Look for die grinders that are built to withstand 1. angle grinders are ideal tools to use with 4 in. runners and deburring in a complex shape casting. Whether the material being removed involves cutting gates. Owing to the nature of the tool.8 hp in both 7 in and 9 in abrasive wheel capacities and are capable of 2.7 m/s² on a pistol needle scaler to limit operator exposure. Look for chipping hammers that provide low vibration through insulated grips and a unique air cushion vibration damping system while providing substantial power in order to remove stubborn materials and coatings. together with chipping hammers and scalers. die grinders can be equipped with different types of carbide burrs that offer maximum removal rates on aluminum or ferrous metals. gates. For difficult-to-reach areas where angle grinders are too large. hand-arm vibrations (HAV) must be taken into account.Material removal is an integral part of the restoration process that determines the overall quality of a finished product. chipping hammers and scalers are the ideal tools for the job. One of the major challenges in material removal is how to increase productivity through reduced downtime and increased yield. To remove the build-up of unwanted burrs or raised edges. FINDING THE RIGHT TOOL FOR THE FOUNDRY Once a mold has been set. Lightweight. or finishing large flat surfaces in oil and gas work. Look for powerful pneumatic angle grinders that offer 2. removing rust or paint.000 rpm to cover all material removal applications. die grinders used with carbide burrs and mounted points are more suitable. For larger surface areas and the removal of thicker materials. they should be cushioned to safeguard against HAV and risk to the user.

Well-balanced tools with composite handles that provide minimum strain to the user mean operators will be able to complete the job with more ease. Drop tests and other extensive testing mean that operators can be confident the tools will continue to deliver high performance even in arduous conditions. ISO standards and national standards. Orbital sanders are better for larger areas thanks to large. Protecting the operator is an absolute priority. Ergonomics.000 rpm in order to obtain the desired finish. the following factors should be taken into account: Safety is paramount. What is the environment like that the tool will operate in? Ensuring that the tool is capable of withstanding a tough environment is essential to reducing downtime – and pneumatic tools typically have a higher durability compared with electric tools. invest in a higher 4/5 . so it is essential to consider the safety features of the tool and the tests it has gone through to ensure it provides maximum safety levels during operation. Also. Once the final sanding has been complete. check how the tool complies with CE. Functionality. What level of functionality is needed to complete the job effectively? For example. an 8. To maintain the maximum level of safety. typically used on flat surfaces.500 rpm 7 in grinding wheel cannot be used on a 12 000 rpm grinder. it is important to adapt its speed to the abrasive material. how long will the tool last before it needs routine maintenance? A tool that can last longer between service intervals will be more cost effective to run.000 rpm to 12. Consider what tests the tools have undergone to ensure durability. When specifying a sander. With such an extensive range of tools on the market.their narrow sanding strip and easy maneuverability. the speed of a grinder should never exceed the maximum operating speed indicated on the abrasive. polishing finishers can be used to provide a final aesthetic touch. which can be more difficult for users to operate. Furthermore. so do not over-specify a tool if a simple one is required. meaning that they provide high performance but are easier to use. some tools feature adjustable side handles that can be tilted in order to fit every operators’ preference. Operators can hold the tool for longer periods of time without excessive strain to get the job done in a quicker and more qualitative way. Note that angle grinders benefit from a low profile that maintains a good operator visibility on the abrasive and operation. Also. circular sanding pads. For instance. Durability. How comfortable and easy are the tools to handle and use? How long are the tools expected to be used for at any given time and what are the vibration levels like? Tools that have been designed with the operator in mind will undoubtedly offer higher levels of comfort. When selecting the tools for the job. which can vary from 6. there are now newly designed tools that deliver excellent power- to-weight ratios. If more complicated or specialist jobs must be completed. For example. How powerful does the tool need to be for the application? More powerful tools often tend to be heavier. is an entry-level tool needed or one that is more sophisticated? Cost is a major decision factor in tool choice. Power-to-weight ratio. it can be difficult to know where to start when specifying. choosing angle grinders that have protective guards and that are proven to withstand the force should the grinding wheel burst are essential for guaranteeing the safety of the workforce. However.

rather than simply the initial purchase cost. www. Fax: 800-228-9096. contact) 5/5 . performing tool that can do the job right the first time. SC 29730. Also. LLC.S. Their durability increases productivity even more through the reduced downtime for maintenance. Choosing high-end material removal tools that can increase the amount of material being removed per minute ultimately improves productivity. (U. and ultimately the bottom line. Only by fully understanding the applications and requirements from the tools can operators make well-informed decisions on the right tool for the application to help increase the amount of material being removed. 800-624- 4735. in addition to the cost of the complete air system – this is another area where efficiencies and increased productivity can be made. their productivity. 1815 Clubhouse Road. Rock Hill.com.cp. Their return on investment can be calculated by multiplying this gain by the amount of time worked in one year. consider the cost over the lifetime of the tools. Lucas Bryk Lucas Bryk is the global product marketing manager for material removal at Chicago Pneumatic Tool Company.