COMMITTED TO METALWORKING SOLUTIONS - Arc Abrasives, Inc.

124 Pages·2013·12.19 MB·English

COMMITTED TO METALWORKING SOLUTIONS

FEATURES
006 Case Studies R
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See how we have assisted companies and their productivity CS-LOK

by using our 5-Step Productivity Analysis.
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A collection of lab reports have been issued at the TS
request of end users or for internal comparative testing
against existing products. Use this section to compare C
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your own operations to a sampling of our library. 078 NDSU
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022 Market Overview NINCE
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Our products serve specific industries and understanding H
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these industries is critical for innovative product development. TS
026 Materials
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Understand the differences in grain structure, backing P
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materials and other important factors to help with your AN
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abrasive choices. S
RETAIL PRODUCT DISPLAY
Showcasing flap discs, quick-lok discs, cut off wheels and
more, your PREDATOR™ retail display will clearly stand out.
Available as a pegboard or freestanding tower, our displays
are free with any qualifying purchase. Contact your local ARC
ABRASIVES, INC. Representative or Customer Service for
more information.
002 | 800.888.4885 ARC ABRASIVES, INC. is a full line abrasives converter.
EXCLUSIVE PRODUCTS
PREDATOR™ RE
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Like our new logo, the PREDATOR™ brand has evolved into
more than just a product, but into a way of thinking and F
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attacking the market to bring value and savings to American P
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manufacturing. We started with an idea to develop a range of IS
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products that would prove to be of value to customers in cost
and performance. This basis has served us well for the past 4
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been proven in products like our Rapid Release System and K

Performance Coating. These products will continue to define
the market so that NO METAL STANDS A CHANCE! P
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Proudly serving the metalworking industry for over 50 years. www.arcabrasives.com | 003
CAPABILITIES
Samples
One very important part of our sales process is to provide samples
for end user testing. We value our customers and make the
delivery of your sample an important priority.
To share our knowledge of the metalworking industry, we allow
you to request the specific samples needed. Going one step
further, we can accompany you on a sales call to assist in closing
your new opportunity.
Our Direct Sales Force
and Manufacturing Representatives
are available throughout the United States,
most of which cover a 200 mile radius.
EDI & Trading Partners
To ease ordering, we use an industry standard EDI exchange
software for the ‘Trading Communities.’ This allows us to receive
your orders electronically, alleviating the need to keep track of
physical paperwork.
Rebate Program
With a continuous interest in creating new business opportunities
with our distributors, a rebate program can be offered for new
sales. Not all distributor needs are similar, so we offer a wide
range of incentive and rebates based on your preferences.
Private Label Program
For select distributors, we can implement and apply an unbranded,
or private label to both packaging and individual products with
your company logo.
Shipping Programs
Through our select carriers, we can ship overnight, provide
competitive pallet rates, and drop ship directly to your customer.
A free freight policy may also be available on select large orders.
004 | 800.888.4885 Stocking programs are available to assist our distributor partners.
CAPABILITIES CAPABILITIES
Productivity Analysis R
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Understanding how our products work within weld removal, deburring and flash removal, and surface finishing
applications is critical. We are continually testing our innovative products on these applications and comparing our F
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results to commonly used products and techniques. This gives us a very clear understanding of how our products will P
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work for you and is the staple of our continuous improvement and product development. Let us show you how we IS
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approach every situation with our 5-Step Productivity Analysis.
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STEP 1: Determine Process CS-LO
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Perform an in depth abrasive cost savings study on-site. The purpose is to completely understand the following:
a. Metals being worked with PS
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b. Fabrication processes in the shop D
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c. Current abrasive applications CS
d. Current products used
e. Customer objectives
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STEP 2: Recreate Conditions N
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Duplicate the end user’s conditions in our lab, eliminating testing in your facility, to develop a cost effective process for
your particular abrasive application.
STEP 3: Demonstrate Modifications B
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Return to the end user with our lab results to perform focused end user testing.
STEP 4: Document Feedback C
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Document all test results with each operator in writing. ITIORFA
STEP 5: Provide Cost Savings and Process Improvements NINCE
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Compare pricing and testing results to document product and process savings. C
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Save production time and costs with our Rapid Release system. www.arcabrasives.com | 005
CASE STUDIES
Agricultural Equipment
Manufacturer of agricultural equipment, including tractors,
combines, hay tools, sprayers, forage and tillage equipment.
Evaluation and Opportunity
Given the major operations involved with this manufacturer,
several locations are utilized within the facilities. Although these
operations are kept separate and involve different applications
there is still product crossover between the two.
Acknowledging heavy stock and rust removal as separate
applications, new products can be suggested to improve production
efficiencies. Although the wire brush that is currently used for
specific applications is a formidable solution, many other products
can be adjusted or replaced for the benefit of remaining applications.
"...Saves hours of sandblasting..."
"...Removes all rust, not just the top layer..."
Billed Time for Rust Removal
Location 1 ............................................................150 hrs/wk Reference Lab Showcase
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Location 2 ............................................................125 hrs/wk
Combined Total .................................................13,750 hrs/yr
Annual Billed Cost x Labor Rate ..............................$412,500
Based on performance results and operator feedback, we can
estimate the following product rates:
Performance New SCD Annual
Improvement Hours/Yr Savings
2 to 1 .................................................6,875 .............$206,250
3 to 1 .................................................4,583 .............$275,000
4 to 1 .................................................3,438 .............$309,375
Product Usage Savings
PREDATOR™ Quick-Lok Disc ..............39,360 ..............$9,052
PREDATOR™ Resin Fibre Disc.............81,000 ............$23,490
Zirconia Resin Fibre Disc ...................6,960 ................$7,238
Surface Conditioning Disc ..................62,008 ............$11,781
Total $51,561
006 | 800.888.4885 An extensive assortment of nonwoven materials are available.
CASE STUDIES CASE STUDIES
Earth Moving Equipment Progressive Die Stamping R
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Evaluation and Opportunity E
Manufacturer of small earth moving equipment specializing in
compact loaders, excavators and attachments. This customer had very specific finishing F
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needs that required two applications for P
Evaluation and Opportunity D
each part - deburring after stamping and IS
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Several production departments were available for evaluation, finishing. The process consisted of
including booms, mainframes, flat beds and rails. Most using several grits and types of grains.
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on certain welds. significantly increased. K

The majority of all applications involved removal of large Product dressing time P
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scratches or penetration marks and mill scale on mild steel was used to wear down A D
plates or sheets. Relative to the required applications, large a new belt to match the ISC
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resin fibre discs are far too aggressive and their maximum required finish. To avoid
potential is not realized. wasting machine down
time or dressing belts to a BO
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ARC believes that we can provide better performance certain grit, a compact grain DE
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by product with a better base cost than what is currently product could last 15 to
being used as evidence in our mounted flap wheel quote and 20 times longer without
operator feedback. We provided a better mounted flap wheel any dressing required.
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at a $1.53 savings per piece. EL
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Conclusion
After much internal lab work
ARC identified 3 main products that provide cost savings in each finishing requirement was CO
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items such as the resin fibre disc and flap disc showed a faster Existing belt usage was cut by nearly C
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cut and a 2 to 1 increase in life with a lower product cost. 50% with a lower product cost. EA
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Performance Coating available on select nonwoven products. www.arcabrasives.com | 007
CASE STUDIES
Aerospace Manufacturing
Manufacturer of military and private aircraft parts.
Evaluation and Opportunity
Operations involved removing machining marks from both 1.5
Silicon Carbide Compact Grain
titanium and aluminum parts. Conventional, single layer silicon
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carbide and aluminum oxide materials were used to smooth the
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flat surfaces and round outside edges. Silicon Carbide
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The titanium parts generated so much heat that conventional 0.5
TITANIUM
abrasive grains broke down, quickly depleting product life. The
use of a compact grain is similar in cost, but has a much longer
life with faster cutting action. 0 2 4 Time (min) 6 8 10
Soft metals like aluminum melt and load into the grain structure, 5
rendering products inoperable. Performance coating has the AO (ARC)
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ability to limit loading by reducing heat and increasing performance AO (Competitor)
nearly 10 to 1. ALUMINUM
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Conclusion Cut (
The products that were recommended by ARC increased life and cut 1
with a 25% reduction in product cost. The compact grain increased
cut rate and usable life by 5 to 1 over the conventional silicon carbide
0 2 4 Time (min) 6 8 10
discs that were being used.
Aerospace Repair Reference Lab Showcase
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Aircraft maintenance and quality control facility.
Evaluation and Opportunity
Required processes included corrosion control, weld removal and general repair of titanium,
nickel alloy and aluminum components.
Surface conditioning materials were currently used for corrosion control applications, but
the current products were not lasting long. During evaluation ARC considered all surface
conditioning grades in order to find the best balance of performance and finish.
Weld removal applications were required for all metals with titanium being the most
demanding. The heat generated during grinding was actually melting the backing pad,
sometimes rendering it useless after one application. Aluminum applications were treated
differently, as the metal would melt, load the discs and prematurely deplete product life.
This is the reason less expensive and much less technical aluminum oxide grains were
being used.

Conclusion
Equivalent materials were recommended for corrosion control applications, providing similar
performance and finish while lowering costs. On titanium, performance increases of 25% to
200% were seen with silicon carbide compact grain, versus the conventional silicon carbide
that was being used.
Operators were impressed with all of the recommendations that ARC provided, but they
were especially appreciative of the performance coating recommendation for their aluminum
components. The Performance Coated PREDATOR™ quick-lok discs easily increased existing
performance by 169% on aluminum.
008 | 800.888.4885 Reduce loading and burning with Performance Coating.