Tyrolit has increased cost-effectiveness by 32% in metal machining

Companies in the metal processing industry are currently facing enormous challenges. The constant need to reduce production costs while simultaneously shortening process times and improving or maintaining product quality is placing many companies under considerable pressure.
Inefficiency in grinding and cutting processes often supplies unnecessary costs and extended production times – both factors that can severely impact profitability.
Tyrolit, the largest specialised manufacturer of bonded grinding, cutting, drilling and dressing tools, fully understands these challenges and offers tailored solutions that increase efficiency and profitability in metal machining. With over 35,000 industrial customers worldwide and as a technology leader, for example as the inventor of the super-thin cut-off wheel and many other innovations, Tyrolit continues to set new standards in the industry.

Tyrolit's CERABOND X technology sets new standards in off-hand grinding. It offers an exceptional combination of high cutting performance, long lifetime and minimal thermal load. Thanks to the self-sharpening ceramics grain, operators achieve a consistently high performance, which drastically reduces the number of wheel changes.
 

The use of CERABOND X grinding wheels supplied a remarkable increase in productivity for one of our customers: the 30% increase in the G-value brought a noticeable increase in efficiency, while the lower thermal load improved the quality of the workpieces. In addition, the deployment of personnel could be reduced by 20% due to the longer lifetime of the tools – a clear optimisation of operating costs. Overall, the customer benefited from a 32% increase in cost-effectiveness, which not only increased the efficiency of the machining, but also provided a sustainable competitive advantage.

For peripheral grinding of cutting inserts, Tyrolit relied on the innovative SOLOTEC technology to significantly increase production efficiency. These grinding wheels enable precise grinding of uneven surfaces and ensure that the feed rate can be increased by an impressive 25% – a crucial factor in reducing machining time. At the same time, the 23% reduction in spindle capacity supplied energy savings without compromising the quality of the results.
Thanks to the increased tool life of 30% and the 25% reduction in process time, customers were able to enjoy a significant reduction in production costs. The overall 20% increase in profitability shows that investing in SOLOTEC technology quickly pays for itself.

The challenge in internal cylindrical grinding often lies in balancing precision and efficiency. By using the ceramics grinding wheels from the COLUMBIA line, Tyrolit has managed to achieve this balance perfectly. Customers have seen a 22% increase in the G-value, indicating a more efficient grinding process and less tool wear. The 20% reduction in cycle time supplied a significant 28% increase in production capacity.

Most notable however was the eight-fold increase in tool life, which drastically reduced the frequency of tool changes. Overall, process savings of 28.3% were achieved, not only reducing costs but also optimising overall production planning.

The machining of railway axles places high demands on precision and efficiency. Tyrolit has achieved outstanding results with its specially developed ceramics grinding wheels. By using these wheels, grinding time has been reduced by 38% and the clock cycle by 37% – a considerable improvement that has accelerated the entire production process. This increased production capacity by a whopping 58.5%, enabling the customer to process more orders in less time. These significant process optimisations resulted in a 34% increase in profitability, which sustainably secured the customer's success and established TYROLIT as a reliable partner for efficient metal machining.

Tyrolit demonstrated the efficiency of STARTEC CG grinding wheels in the centreless grinding of solid carbide green bodies. The application of this technology enabled a significant reduction in spindle capacity of 23%, resulting in remarkable energy savings. In addition, tool life was increased by 32%, which extended the intervals for tool changes – a clear advantage in terms of production costs. Process time was also reduced by 22%, which supplied an overall 30% increase in cost-effectiveness.

Thanks to optimised surface quality and reduced energy consumption, this application demonstrates the significant added value that Tyrolit customers can achieve by using their highly specialised grinding solutions.