|Our Business||Ceramic grinding|
|Work style||Maintains high-quality for low-volume multiproduct production mainly for semi-conductor manufacturing equipment.
In order to increase machine operation rate, we have kept work optimization constantly in our minds while automating our equipment, and have enabled 24-hour operation.
|Machining materials||Ceramics (alumina, silicon carbide, sapphire, zirconia), carbide, difficult-to-cut material|
|Number of workers engaged in machining||7|
|Machinery used||Machining center x 8, rotary grinder x 3, surface grinder x 1|
|Adopted filtration||MTR, FWC (SGL precision filtration equipment)|
We tried a variety of products such as paper filters and span filters, but they soon became clogged. Coolant immediately became cloudy, gave off a terrible rotten smell, a slimy sludge-like sediment formed, and we had to work with this supernatant liquid. We also tried centrifuge separators, which delivered certain benefits, but a lot of time was required every day to perform maintenance, sludge containing ceramic became crispy when dry, and we had a lot of trouble removing it. We tried various ideas such as putting in sandbags, but there was no change in the labor involved. And annoyingly, the equipment then broke down after three to five years. We finally stopped using it, stored sludge in a water tank to the very limit, and settled on a method whereby we had an industrial waste treatment company draw out the sludge with a vacuum.
Since around 20 years ago, SMK has been receiving orders for wire cutting from SHINKO CO., LTD., and have been getting them to regrind rollers for us.
We recommended that they use paper filters. However, they did not because they felt that there was no need for them. SHINKO was having trouble with cloudy coolant, and were not particularly interested in using paper filters, so we took an "MTR" test machine to their facility to carry out a filtration test, and they completely changed their opinion.
SHINKO installed our filtration equipment on their grinders, and then finished up work after verifying operation.
The following morning they were surprised to find that the coolant had been completely filtered of sludge, and that "what had been mud was now clear water".
The need for wheel dressing has been completely eliminated since we started using filtration equipment. Approximately 0.1 mm was shaved off our grinding wheels almost every day, for a total of around 3 mm a month. As a result, pockets had become clogged, however, this problem was completely resolved. It might be too much to say that our grinding wheels now last twice as long, but we definitely feel that they last at least 1.5 times longer.
Furthermore, we assessed working conditions on grinders during work and "no abnormal noises were witnessed", allowing work to proceed to completion without any interruptions.
SHINKO tends to carry out low-volume multiproduct production, and we also have many jobs involving the production of just a single product. Defects mean a complete waste of both materials and time. And yet, we previously believed that "the cause of defects was unexpected chipping occurring despite no mistakes in procedures or operation", and we were frequently forced to redo work over again. This has now been reduced to "zero". We now understand that it was the unexpected chipping caused by sludge that could not be filtered adhering to workpieces that resulted in product defects.?
Previously, we had been sending out drums filled with sludge to an industrial waste treatment company four times a year (approx. 5,000 yen/drum) Complete replacement with new coolant (100,000 yen/drum) each time became unnecessary. We then only had to top up with the amount that evaporated, and coolant replacement was no longer required.
MTR: Machining centers → every 3 months, rotary grinders → every 2 weeks, surface grinders → every 3 weeks
FWC: Machining centers → every 2 months
Coolant pump breakdowns which once occurred frequently due to clogging no longer occur.
Furthermore, the life of consumable parts such as rollers and nozzles has been extended.