To optimize its production, an auto parts manufacturer has stepped up its game and closely examined its processes. The medium-sized company identified deficiencies in the machining of a steel roll. The previously used reamer wore out too quickly and operated unreliably. A tool from ISCAR provided a remedy. Since the BAYOT-REAM reaming system has been in use, tool life has significantly increased, and the supplier saves more than 60 percent on tool costs.
In 1948, Ludwig Wagner founded his company in Fulda, Hesse. Initially, bicycle parts such as hubs and pedals were produced. 15 years later, the company entered the automotive industry. Today, Wagner GmbH & Co. KG produces solenoid valves, oil spray nozzles, assemblies, as well as stamped, turned, and milled parts to specification with a modern machine park. Customers include international car and truck manufacturers. The family-owned company with nearly 500 employees also supplies the plant and shipbuilding industries.
To remain competitive, Wagner's production processes are under constant control. The responsible parties identified deficiencies in the machining of a roll made of 11Mn30+C automatic steel. The tool used had a highly fluctuating tool life. Furthermore, the surface quality left much to be desired. The consequence: too many defective parts were produced, and the process required a high personnel control effort. Therefore, the Hessians searched for a suitable alternative.
During one of the frequent visits by the ISCAR team to the company, the machining problem came up. 'We regularly visit our customers to inform ourselves about current challenges,' explains Marco Hoffmeister, Technical Consulting and Sales at ISCAR. His colleague, application technician Mirko Streng, adds: 'After a thorough analysis, we propose a suitable tool.' For the machining of the steel roll, the experts recommended ISCAR's high-speed reaming system BAYOT-REAM. To clarify matters, the project partners agreed on tests under practical conditions - with impressive results.
Compared to the competitor's product, the ISCAR reamer made of the durable cutting material IC30N was significantly faster at a drilling depth of 17 millimeters, and the feed rate was five times higher. Instead of the previously processed 1,500 components, BAYOT-REAM achieved 7,000 pieces. For Wagner, this was reason enough to choose ISCAR.
Long tool life and optimal chip flow
With the BAYOT-REAM reaming system, ISCAR has developed a flexible tool. It consists of a steel shank, a replaceable carbide reaming head, and a quick-change bayonet connection. The reaming head is mounted using a special clamping key. A time-consuming removal of the base holder is not necessary. Another advantage is the internal coolant supply. This ensures that each cutting edge is effectively cooled. As a result, long tool life and optimal chip flow are guaranteed.
ISCAR offers the reaming heads in diameters from 11.5 to 32 millimeters for machining depths of 3xD, 5xD, and 8xD.
BAYOT-REAM is on a success track at Wagner. The processes now run reliably, the machine operators no longer need to monitor constantly, and they have capacities free for other activities. The surface quality meets the company's expectations with a very good value of Ra=0.9. The machining time per component has been reduced from two seconds to 0.3 seconds. BAYOT-REAM ensures significantly longer tool life. In combination with significantly shorter cycle times, Wagner saves 66 percent on tool costs.
The company also rates the collaboration with ISCAR employees very positively. Regular contact helps to identify problems and develop solutions. Furthermore, the auto parts specialist appreciates the technical expertise and quick response time of ISCAR's field service.
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