Toolox 33 in knife support cuts downtime at recycling plant
Equipment for recycling plays a crucial role in environmental stewardship. And as any maintenance manager at a recycling plant knows, a healthy recycling business depends on healthy equipment. It’s no wonder, then, that managers view equipment uptime as their top priority. So when one manager’s wood recycling machine broke down after failure of the machine’s knife support, he started looking for a reliable solution.
The maintenance manager turned to Toolox® 33. The strength of Toolox, combined with its superior properties in the workshop, made it the ideal solution. And since Toolox33 was available at the SSAB distributor Industrias Trimar, close to the recycling plant, machine downtime could be kept to a minimum.
Toolox brought the following benefits:
Its low carbon content significantly increased machining speed.
Its low stress level made it easy to achieve the close tolerances required by the support.
Guaranteed high homogeneity within and between plates assured top quality.
SSAB’s unique quality control process — each and every plate is individually tested according to strict standards — ultimately helped the plant optimize its operations, benefiting both the environment and the business.
Toolox 44 helps rev up productivity in the automotive industry
A specialist in the manufacture of forged parts for the automotive industry, Krenhof Schmiedetechnik AG produces its own tools to make batch production parts. The tools are mostly surface engineered to give them the high wear resistance and durability they need.
Even when surface engineering is performed properly, cracking can pose a problem. Material can get caught on the edges of the cracks during the forging process, leaving scar-like marks on the forged items. This results in more rejects than good parts, especially in smaller production batches.
“With SSAB’s Toolox 44, we’ve finally found the material we had long been searching for – a material that isn’t surface engineered, yet still has the same properties,” says CEO Matthias Hartmann.
The first success of the new tool steel has been achieved with the construction of prototypes. Every year, the company manufactures 100 different components for new vehicle models – and these are now produced exclusively using tools made of Toolox engineering and tool steel.
“You normally need to compromise on hardness if you want to achieve a high level of crack resistance, yet Toolox enables us to achieve the right balance between hardness, toughness, and heat resistance,” adds Hartmann.
Krenhof has also started using Toolox 44 in the shear blades used for rod cutting. Breakages have almost been eliminated and the blades’ lifetime has increased tenfold.
ThyssenKrupp Tallent extends die life and productivity with Toolox 44
ThyssenKrupp Tallent UK is a leading manufacturer of pressed components for some of the biggest names in the automotive industry. The company manufactures its products cost efficiently using assembly lines with automated robotic welding.
ThyssenKrupp Tallent depends on just-in-time deliveries to keep production up and running. The unavailability of components can bring the entire manufacturing process to a halt, resulting in serious cost consequences. Premature cracking of the company’s blanking die threatened to jeopardize its ability to consistently produce quality components and secure future orders — and lose business altogether.
The company turned to Toolox 44, deciding to produce and nitride a new die to protect the edges during blanking.
Soon after the Toolox die was put into production, it became obvious that it was far superior to dies that use conventional tool steels. Toolox 44 remained intact and the die became a major success, receiving more than 255,000 blows without any negative effects.
Using Toolox 44 has significantly improved the die life, bringing greater productivity, improved profitability and more on-time deliveries. The company has also seen a reduction in die manufacturing time, resulting in lower production costs.
And because the heat treatment is carried out by SSAB, high quality and consistency are guaranteed in every piece of steel. In fact, when a customer buys Toolox, SSAB guarantees that all of the properties in every piece of steel meet stringent quality standards — a unique offering in the market today.
Ready-to-use and workshop-friendly, Toolox 44 helps customers deliver to a demanding market
As this Spanish company faced increasing domestic and global competition as well as pressure from customers, it turned to Toolox® for a workable solution.
Spanish companies are becoming exposed to an increasingly discerning and competitive marketplace. Customers are demanding shorter delivery times and lower prices but at the same level of quality for their parts.
Metalúrgicas Arnal, based in Moncada, Spain, experienced this very situation.
The company specializes in manufacturing equipment and tools for the high-speed rotation of turned and deep-drawn parts. Finished parts are supplied to the lighting sector (lamp accessories) and the supply industry. Although the company sells mainly on the domestic market, it also exports to countries both inside and outside the European Union. It owns several high-speed manual lathes with numerical control.
These lathes shape a range of different materials, such as soft steel, stainless steel, copper, brass and aluminum in thicknesses between 0.5 and 1.5 mm (0.020 and 0.059").
Juan Arnal himself explains, “As competition became increasingly more difficult both nationally and internationally, we were forced to look for a completely new solution, which we finally found in the form of Toolox steel from SSAB.”
Before using Toolox engineering and tool steel, the company used 1.2379 steel for the molds that was hardened to 60 HRC. The processing time for pre-machining and subsequent machining was roughly 12 hours, and in between these two processes the molds required hardening. In addition to a total waiting time of around one week, this scenario generated high manufacturing costs and potential risks due to the heat treatment. For these reasons, the company used other materials such as nitrided F-127 or bronze (400 HB) hardened to 60 HRC, alternatives with considerably lower durability than 1.2379. These solutions produced points on the mold due to surface fatigue that were transferred to the finished parts.
“Since Toolox requires no heat treatment, the time required for manufacturing a mold has been reduced to only 8 hours, namely to the time for mechanical processing,” explains Arnal.
Antonio López, in charge of automatic turning, says that “in the meantime, we’ve been working with Toolox molds for more than half a year and they are still exactly the same as on the first day.”
Spanish machining workshop Herso SL has long been specializing in machinery for the plastics and rubber industry. Companies often turn to Herso as their first choice for meeting their machinery maintenance needs. That’s just what happened when a recycling plant decided they needed to repair their recycling equipment for rubber car tires.
Herso knows that guaranteeing high-quality steels for recycling equipment is crucial — something that’s increasingly difficult to control using conventional alloy steels. The market often offers a mix of steels with different origins and therefore different properties. And most steel distributors don’t state who has manufactured the steel, complicating quality control even more. The company needed to fully assure high quality while not raising the price to its end customer.
For two of the most sensitive components in the machine, Herso decided to use Toolox 33. Since Toolox 33 plates are tested individually and come with a product certificate stating the test values, Herso gained peace of mind knowing exactly what their steel contained. Manufactured in quenched and tempered plates, Toolox exhibits a more homogenous structure than the large, forged round bars that would have been the alternative.
Using Toolox, Herso can expect increased overall performance of the recycling machine pieces. The Toolox plates bring the following benefits:
Higher strength along with increased crack resistance
Measured and guaranteed quality
Less machining and consumption of inserts
Oxy-cutting capabilities without the risk of cracks or excessive hardness in the edge, thanks to the low carbon content of the steel
Toolox transforms plastic into productivity in bottle recycling machines
Nacher Mecanizados SL has been manufacturing high quality machined components since 1978. Even before the economic downturn in Spain, the company decided to specialize in machining large pieces, giving them a competitive edge over many of their competito
A recycling plant needed to carry out maintenance on one of its machines recycling PET plastic bottles. For the cutting blade supports, they wanted a more reliable steel than the previously used. At the same time, they asked for the shortest delivery time possible so they could restart their recycling operations.
The company turned to Toolox from SSAB. The combination of high yield strength and much higher toughness than alternative steels makes Toolox perfect for heavy machinery.
The low residual stresses made it possible for Nacher Mecanizados to machine the pieces in just one setup. Even the milling speed saw improvements thanks to Toolox’s homogenous microstructure. And because Toolox steel is delivered in flat shapes, it presented a much more practical alternative than the alloyed round bars normally used.
Manuel Nacher, owner of Nacher Mecanizados, says, “Toolox gives me the possibility to manufacture high-performance components very effectively. The superior mechanical properties of Toolox and the unique quality control of the product also make it possible to offer a very reliable product to my customers.”