CS1-E Tridex Technology Burr-Free Electrochemical Cutoff Machine Download Machine Brochure

At Glebar, we are committed to providing state-of-the-art applications and solutions, which means we are always engaged in process development procedures to ensure our equipment meets our customers’ expectations. 

For example, our customers wanted an easier, more reliable way to check the electrolyte levels of their Tridex ECG Cutoff & Grinding machines without having to engage in the tedious and less accurate manual process. To achieve this, our team developed an enhanced electrolyte tank featuring digital ultrasonic sensors that connect with an I/O link to the HMI screen enabling better grind management, improved grind efficiency, and reduced downtime. 

Challenge

Operators use float hydrometers to measure the electrolyte’s salt density and perform visual inspections of the clean and dirty electrolyte fill levels. 

These tests:

• are manual and operator-dependent processes.
• provide insufficient data to accurately plan for electrolyte change.
• reduce the quality of the grind increasing scrap rates.
• result in lower process capability.

Current Process

A high-powered laser beam cuts the tubing by melting it leaving a rough edge and slag. Tubes and other parts are typically cut one at a time limiting production rates.

Challenges

Heat sensitive applications may limit the use of the laser for cutting. Laser cutting leaves recast and heat-affected zones, affecting the tube's quality and increasing scrap rates. Beam deflection when cutting through a tube can affect accuracy and cause damage. Laser cutting is not capable of creating clean and sharp edges. Therefore, time-consuming secondary processes to deburr tubes and remove any debris are required. Delivering a process that cuts tubes to length, maintains a high level of quality and accuracy, leaves no recast or slag, and improves production times.

Current Process

Zirconium tubes are cut one at a time using carbide tools on a lathe. A lathe cutoff leaves burrs requiring deburring to achieve a smooth surface finish. Carbide tooling wears quickly when cutting zirconium and is expensive.

Challenges

Deliver a cost-effective process to cut zirconium tubes which reduces the number of steps in production. Zirconium is highly flammable, and a dull carbide tool can cause the material to overheat and catch fire. Zirconium fires are dangerous and very hard to extinguish.

Challenge

Parts are cut using abrasive cutting saws, conventional abrasive grinding, wire EDM or laser cutting; slow processes resulting in long cycle times. Potential to expose material to high heat leading to heat affected zones, recast, and slag. Requires secondary process to deburr parts and remove any surface debris which reduces productivity.

Design a process that can provide a burr free cut without recast, slag, or heat damage while maintaining a high quality part and reducing cycle time. Reduce the number of steps in the production process.

Challenge

Tubes are cut one at a time using a standard abrasive cutting saw which leaves burrs. Requires secondary process of wire brushing and tumbling to deburr tubes and remove any debris. Older machines have poor accuracy and outdated safety features. Debris from abrasive cuts cause frequent maintenance issues.

Design a process that can cut multiple tubes burr free simultaneously without damage from debris. Reduce the number of steps in the production process. Provide a machine that won’t deteriorate over time.