PFERD’s New Solutions Showcased at FABTECH 2018

PFERD recently attended the FABTECH 2018 show, from November 6-8 in Atlanta, Georgia. FABTECH is North America’s largest event for the metalforming, fabricating, welding, and finishing disciplines, showcasing the latest innovations in metalworking technology. FABTECH provides comprehensive education on the industry’s newest advancements and best practices, as well as networking opportunities across a wide spectrum of industries. This year’s event drew more than 35,000 attendees and over 1,500 exhibitors.

At FABTECH 2018, PFERD featured new products being introduced to the market, and highlighted components in our PFERDVALUE® program with a focus on time saving solutions.

PFERD New Product Launch

PFERD unveiled a range of products designed for milling, grinding, and surface conditioning applications. Our product displays and live demonstrations showed how our new solutions increase time savings and boost profitability.

The new products we introduced at FABTECH 2018 included:

  • POLIVLIES® interleaved flap disc comprised of non-woven material combined with an aggressive ceramic coated abrasive
  • Our CC-GRIND®-STRONG grinding wheel, composed of stacked coated discs combined with bonded abrasive support
  • A CERAMIC SGP STEELOX 1/8” thickness grinding wheel, suited for light grinding and cutting in the pipeline industry
  • Our OMNI cut carbide burs designed for aggressive removal on steel, stainless steel, cast iron, and non-ferrous metal
  • The CERAMIC SG COMFORT hybrid grinding wheel, featuring a rough grinding wheel combined with a coated abrasive top layer for high stock removal (4.5” and 5” diameters available)

The PFERDVALUE® Program

Product demonstrations in our grinding booth and finishing station highlighted PFERD products featuring core elements of our PFERDVALUE® program.  Namely, ways in which we focus on operator health and safety and how we help our end users save time and maximize productivity—a core aspect of the program.

As always, the PFERD team greatly enjoyed interacting with all FABTECH 2018 show attendees and are excited for the resulting opportunities generated from our conversations and interactions.

To learn more about the new PFERD metalworking solutions introduced at FABTECH 2018 or to about our metalworking capabilities, contact us today.

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Restoring Equipment Condition and Performance with Non-Woven Abrasives

Keeping your equipment running at peak efficiency is essential for manufacturing and fabrication operations. However, repairing machinery fatigue can become costly and grind operations to a halt. Non-woven abrasives – cost-efficient surface cleaning alternatives with many different applications across a range of material surfaces – can help your machinery continue to perform in top condition.

When used regularly, non-woven abrasives boost equipment performance, extend the life of expensive investments, and efficiently handle the level of demand your operations require.

Advantages of Non-Woven Abrasives

Non-woven abrasives offer a number of benefits when used across diverse industries, including aerospace, transportation, energy, and related maintenance and repair operations (MRO), as well as in metal fabrication shops. Modern manufacturing processes frequently rely on non-woven abrasives to increase productivity, maximize overall efficiency, and keep operating costs down.

Waterproof and highly resilient, non-woven abrasives also offer:

  • Finish consistency and reliability – ensuring you always get the results you want
  • A high-precision cut with a low base stock removal
  • Increased safety in comparison to other grinding methods
  • Availability in a range of shapes and sizes, providing solutions for irregular surfaces and dimensions

Applications in Aerospace

PFERD POLICLEAN® Non-Woven Discs

In the aerospace sector, superior quality and finish of components is essential to operation. For example, airframes – the mechanical bodies of aircraft – are subject to a wide range of stresses and other factors that can contribute to damage and corrosion. Non-woven abrasives offer an opportunity for aerospace manufacturers to increase the durability and longevity of airframe components, and MRO professionals have seen the benefits of non-woven abrasives for addressing common maintenance issues in airframes.

MRO for airframes is expensive and the results are often short-lived, but using non-woven abrasives outperforms conventional surface conditioning products by as much as four times in terms of effectiveness. Using non-woven abrasives offers a demonstrably longer service life, cut rate consistency, and a superior ultimate finish when compared with competitive products. In addition, non-woven abrasives are more affordable, demonstrating a further positive impact on the bottom line.

PFERD offers a range of products suitable for airframe maintenance, such as COMBIDISC® and POLICLEAN® non-woven discs.

Applications in Transportation

PFERD POLINOX® Cross Buff

The transportation industry has also realized the superiority of non-woven abrasives over traditional methods—for example, in piston-driven engines, such as those found in automotive and locomotive vehicles, scuffed pistons can lead to shortened service life and critical engine failure.

However, providing a proper surface finish on bores ensures that pistons will have a proper clearance, while simultaneously limiting bore distortion caused by exposure to heat. Providing this level of surface finish has traditionally been quite expensive, but using non-woven abrasives such as cross buffs enables manufacturers to control finishing costs while providing a superior product.

PFERD’s POLINOX® cross buffs are an ideal solution for this challenge, as they excel at ­interior deburring and providing superior surface finishes in non-ferrous metal bores.

Applications in Renewable Energy

As renewable energy becomes more prominent, the sector has also realized the benefits of cost-effective surface finishing via non-woven abrasives. Wind turbines offer a fine example of a long-term problem that can be virtually eliminated through proper surface conditioning.

The rotor blades of wind turbines are subject to constant exposure to temperature extremes and inclement weather, making them susceptible to a range of corrosion, damage, and stresses. Considering that blades make up approximately 1/5 of the total cost of a wind turbine, they are not easily replaced without incurring great expense. Yet, leaving unclean, rough, pitted, or damaged blades greatly decreases the efficiency of the blade—and subsequently, the entire turbine.

Conditioning wind turbine rotor blade surfaces with non-woven abrasive belts can restore functionality and drastically reduce service downtime and costs when compared to blade replacement or other service methods. This enables renewable energy producers to maintain steady power generation levels and meet tight quotas.

PFERD’s non-woven abrasive belts are an excellent solution for refinishing surfaces after repairing cracks or other damage in aluminum blades, and also for prepping blades for protective coatings.

Choosing the Right Non-Woven Abrasives

Applying a PFERD COMBIDISC® Non-Woven Disc

In the world of abrasives and cutting tools, PFERD’s expertise and knowledge are second to none. ISO 9001 certified and backed by more than 200 years in the business, you can rest assured knowing our PFERD staff is skilled at understanding the unique specifications associated with each surface conditioning project.

Trust in PFERD to provide outstanding, premium quality tools and abrasives for all your manufacturing or fabrication needs. PFERD has a large variety of non-woven abrasives to meet the needs of virtually all projects of varying dimensions and surfaces.

To find the right tool for your surface conditioning project, click here to view our full selection of multipurpose non-woven abrasives.

PFERD Featured in the August 2018 Edition of FAB Shop Magazine

The August 2018 edition of FABSHOP Magazine Direct.
The August 2018 edition of FAB Shop Magazine Direct.

PFERD was recently featured in the August 2018 edition of FAB Shop Magazine Direct. The article interviews PFERD brush product manager Imre Karetka, who speaks about the importance of deburring, the various deburring options available, and the role of deburring and surface conditioning in automation, which maximizes efficiency in industries that deal with high production volumes on a daily basis, particularly the automotive industry.

In machining terminology, a “burr” refers to a rough edge or ridge on a metal workpiece that remains after the action of a cutting tool or grinding machine. Typically unavoidable byproducts of the machining process, burrs can be problematic if left on the final product. Deburring, as its name suggests, is the process by which burrs are removed, ensuring a smooth and consistent surface finish.

Haven’t read the article yet? Below, we’ll provide an overview of the key takeaways and offer insight into some of PFERD’s deburring solutions.

The Importance of Deburring

Few industries impose stricter safety demands than the automotive industry. Automobile parts and components must be designed to meet stringent specifications and tight tolerances; deburring is a critical manufacturing step to ensure adherence to these requirements.

Internal automobile parts are constantly moving to keep a vehicle functioning smoothly. As Mr. Karetka points out in the FAB Shop article, burrs left behind during manufacturing can break off during operation, resulting in metal flakes flowing within the vehicle’s internal mechanisms. Foreign objects in the transmission, for example, will negatively affect the vehicle’s overall performance and present several safety hazards.

Mr. Karetka also discussed deburring tools as a means of automotive component surface conditioning, such as for camshafts. Bearings, called journals, must be properly finished to facilitate the flow of lubricant onto the camshaft. Improper surface preparation results in lack of lubrication and accelerated wear of metal parts, which causes overheating and seizing of the engine.

Creating Customized Deburring Solutions

Primarily focusing on deburring applications in automation, the article noted that many industries, especially automotive, regularly mass produce parts and components as part of their daily operations. This production process, however, can present unique challenges.

First, conventional manual deburring methods are often inadequate due to time constraints and increased cost of manual labor. Second, space constraints in some facilities can limit the size of brushes that can be used in automated deburring and surface preparation techniques.

To overcome these challenges, PFERD partners with industrial CNC and robotic OEMs to develop customized deburring solutions for specific applications. Our team also configures the grit and wire sizes, increasing them as required to maintain deburring efficiency while minimizing equipment and tool size.

Tackling Deburring Challenges in Automation

At PFERD, we understand that unique situations call for different deburring solutions. To address these different use cases, we offer a range of automated solutions to meet the requirements of almost any industry including:

  • Abrasive brushes –Available with various abrasive materials including aluminum oxide, silicon carbide and ceramic oxide, M-BRAD® brushes are suitable for surface conditioning on a variety of materials including wood, glass, and most metals and alloys.
  • Carbide burrs – Known in the industry for precision, consistency, and concentricity, our carbide burrs are designed for deburring machined holes in metals of virtually any composition or strength. A range of general-purpose burs – as well as material and application specific burs – gives users choices for the optimum solution for their specific application

With more than 200 years of experience in the business, PFERD has established itself as an industry leader providing single-source cutting, grinding, and finishing solutions for many specialty applications. In addition to our standard catalog offering, our team of engineers and technical staff has the experience and expertise to develop customized deburring and surface conditioning solutions to meet customer project-specific requirements. We work closely with clients at every stage of the design process to ensure that our products exceed expectations.

To learn more about deburring automation, check out our recent feature in FAB Shop Magazine Direct. If you’d like to speak with a member of our team for more information on PFERD’s automated deburring and surface finishing services, contact us today.

The  Benefits of High Performance Bur Engineering

Almost any operation involving metal cutting, fabricating, or machining requires secondary processing steps. Removal of weld seams, raised edges, jagged shards, and other imperfections can undermine the part’s performance and detract from its appearance.

steel-cut-bur

With PFERD’s high performance carbide burs, however, manufacturers can easily perform any needed machining while ensuring that their products receive as smooth a finish as possible.

Because they’re designed with particular materials and applications in mind, PFERD’s high performance carbide burs can significantly increase productivity and reduce manufacturer’s operating costs without sacrificing performance.

Material Considerations

While PFERD offers a range of single and double cut burs for general-purpose milling, certain materials pose unique machining challenges. Our material-specific burs will deliver optimum removal with an excellent surface finish.  Their innovative tooth geometry and premium-quality tungsten carbide construction allow for:

  • More aggressive cutting
  • Reduced chatter, noise, and vibration during operation
  • Safe material removal by generating large chips instead of potentially dangerous respirable dust

The following is a brief overview of the various cuts available in our High Performance line, and their unique advantages.

Type

Works best with…

Advantages

CAST Cut Bur

Cast irons Less noise, smoother milling operation, very high chip removal

STEEL Cut Bur

Steels and cast steels Shorter machining timelines, extremely high stock removal

INOX Cut Bur

Stainless steels and hard alloys Enhanced tooth geometry, superior finishing, reduced heat generation to prevent discoloration

ALU Cut Bur

Aluminum, other non-ferrous or soft metals High stock removal, reduces loading

Application Considerations

In addition to burs designed for work on specialized materials, PFERD’s high performance range includes carbide burs designed to suit specific applications.

Type

Works best with…

Ideal for…

MICRO Cut

Automated OR handheld machining Precision applications, high-quality finish

EDGE Cut

Versatile handheld edge profiling
  • Precise, guided work on edges
  • Chamfering, deburring and edge breaking/rounding
  • Steel and aluminum construction

TOUGH cut

High-impact applications that typically result in chattering and broken bur teeth Tough operating conditions in shipyards and foundries

 

Established outside of Cologne in 1799, PFERD has supplied manufacturers with premium metalworking solutions for hundreds of years. In 1942, PFERD was granted their first patent on a “rotary milling cutter”, which later evolved into our present-day line of carbide burs. Over the centuries, PFERD has been committed to offering high quality “single-source” solutions for grinding, cutting, hand finishing, and specialty applications.

Regardless of your industry or application, our high-performance burs can help you achieve maximum productivity and cost effectiveness in your machining process.

To learn more about our products and services, visit our website today.

Bringing German Precision and Expertise to the US Large Diameter Cut-Off Wheel Market

While perhaps a bit of a niche market, the demand for large cut-off wheels is increasing due to the strengthening of the US steel industry.  Applications such as cutting of solid metal in rolling mills, rail manufacture, foundries, and other large-scale cutting operations,  call for a highly specialized product that is custom engineered for each specific process and material.  Leveraging our engineering expertise in abrasives and industry experience in various global segments, PFERD has brought this capability to the US market .

Large Diameter CutOff Wheel
PFERD Large Diameter Cut-Off Wheel

We’ve recently expanded our North American offering in large diameter cut-off wheels to a product range that has been popular overseas.   While we do offer a range of wheels for stationary cutting applications in our standard US offering, large diameter wheels require specific know-how and made-to-order competencies. PFERD’s prowess in this area was recently highlighted at the International Hardware Fair in Cologne, Germany where we featured manufacturing capabilities of cut-off wheels up to 2,000mm (about 6½ feet).   “In the large market, there are only 4 companies in the world that can make the 2-meter diameter cut-off wheel,” said National Account Manager Tim Lee. “We’re one of a very elite group in that respect.”

Tim has been tasked with the job of building awareness for this capability across North America.  The need for an industry expert that can talk

PFERD Large Diameter Cut-Off Wheel Account Manager
PFERD National Account Manager Tim Lee

the talk with the end user, identify the requirements of the specific application, and communicate that to the engineering team, is crucial.  With 28 years in the abrasives industry, Tim is an experienced leader in this field and can solve problems that customers themselves may not be unaware of.  His expertise in this sector is extremely valuable when identifying and delivering solutions for these complex applications.

PFERD’s combination of engineering expertise, manufacturing capabilities, and industry knowledge in the unique and often challenging application of large diameter cut-off wheels enables us to deliver the solutions needed in the steel industry.   To learn more call us today or email our industry expert directly at ldco@pferdusa.com

Pipeline Industry Insights from a Career Spanning Five Decades

Recently, thousands of pipeline industry professionals converged in Tulsa  for the Steward School 2018 kick-off event. In addition to recreational activities such as the Annual Charity Golf Tournament and Lincoln Electric BBQ at the Steward School, participants come together to gain new skills through training sessions. This also a great opportunity for industry sponsors to meet with members and discuss product solutions.

Michael Roche in the Field

Among the participants at this year’s Steward School event was PFERD’s Pipeline Market Manager Michael Roche, an honorary member of the Pipeliners Union Local 798 since 1990. Through Michael’s ongoing relationship with the Union, PFERD has served as a sponsor for 15 years. We provide abrasives designed for the pipeline industry and get a first-hand look at how industry professionals are using our products in their projects.

“The market is so busy right now,” Michael said. “There’s going to be an explosion of jobs within the next month…Business is picking up in this sector, and the trend looks to continue for the next 5 years, maybe 10,” he said.

With a pipeline career spanning more than 50 years, Michael is a great candidate to provide such insights. Getting his start in 1964 as an apprentice with a pipeline company in England, he’s traveled the world and built a solid reputation as an industry expert.

“I’ve worked in over 30 different countries, and lived in many for months or years,” he said. In his role as a troubleshooter for a major pipeline company in Tulsa, he could expect phone calls to send him anywhere in the world.

“You didn’t know where you would go the next day,” he said. “Based on the problem with the equipment, you didn’t know how long you’d be there. You had to be there until the job was rectified.”

Working with PFERD, Michael consults with pipeline professionals on the frontlines and offers solutions tailored to each job. The tools must be able to withstand unpredictable and extreme weather conditions and comply with stringent safety requirements. We have more than 6,000 tools for surface finishing, cutting, rust removal, deburring, and more. Michael is a great resource for identifying which tools will be best for each stage of pipeline construction work.

We appreciate Michael’s guidance both internally at PFERD and externally with those who use our products on a daily basis. To learn more about our specialized pipeline solutions or discuss your current needs, please feel free to contact us at your convenience.

Eyes in the Skies – What’s Driving Aerospace Forward?

New technologies and materials have been revolutionizing just about every industrial sector. The trend toward greater efficiency without sacrificing safety has largely led these new shifts. The aerospace industry is among those facing changes.

The Role of Lightweight Material in Aerospace

In an effort to improve aircraft performance and fuel efficiency, many components are now being made with composite materials. These materials provide the same high-strength characteristics as other materials, but are a lightweight option.

Already, aircraft structures including fuselage, wing parts, nacelles, control surfaces, floor beams and even helicopter rotors are being made with composites. Carbon fiber reinforced plastics (CFRPs) are by far the most common materials being used in this application.

Why New Materials Require New Tools

Carbide Bur
PFERD FVK/FVKS Style Bur

Because these are newer materials in aircraft design, new tools and processes are needed to work with them. When cutting and machining these composite parts, workers have to be careful to avoid issues like delamination, fiber tearing, or heat damage. Traditional machining is made difficult because CFRP often splinters off into an abrasive dust.

In some cases, the traditional tools of this trade need to be reimagined for this particular material. PFERD’s Aerospace Market Manager, Chad Waltemyer, has been working closely with our product engineers to develop customized abrasive media to cut, grind, and contour these various composites. One example is with carbide burs where tooth geometry and spacing are critical to the performance of the tool.  PFERD FVK/FVKS style burs provide excellent cutting coefficient on most CFRPs for contouring edges.

Finding a Custom Solution for the Aerospace Market

As the Aerospace Market Manager, Chad helps customers get what they need-even if the necessary product doesn’t exist off-the-shelf.  For the past year and a half he’s been working closely with manufacturers in the aerospace industry to understand current trends and the specific requirements for their unique applications.  Communicating those needs to our engineering team allows us to review each application and project and design the perfect product to fit.

Composite Brush
PFERD M-BRAD Composite Brush

Where Aerospace Manufacturing is Heading

As a partner to customers and leader on the shop floor, Chad sees a paradigm shift in deburring applications. Where operators have historically performed this operation via hand tools, he’s now seeing this application increasingly being performed on CNC machines.  He’s sees strong interest and demand for PFERD’s M-BRAD® composite brushes which is ideal for this application. Employing automation to this task has resulted in major cost reductions and processing time – all key objectives in the manufacturing process.

As a leading manufacturer of premium tools and abrasives, we are excited to see what new developments will come about in the aerospace industry.  To learn more about our custom capabilities, feel free to call (262) 255–3200 or email sales@pferdusa.com.