| Application |
| Forming non-ferrous tubing on a state of the art high production tube mill |
Service Conditions |
| 1. | Forming non-ferrous tubing |
| 2. | Production Rate greater than 160 meters/minute |
| 3. | Twenty-four hour six days per week production |
| 4. | Scheduled maintenance every two weeks |
| Problems |
| 1. | Component availability only from a non-domestic source |
| 2. | Unscheduled downtime due to random chipping of the ceramic tooling |
| 3. | Tubing defects resulting from chipped tooling |
| 4. | Difficult technical communication with suppliers |
| Solution |
| 1. | Replace existing ceramic rolls with Accuratus sintered silicon nitride ceramic |
| 2. | Control precision manufacture of the rolls to maximize intrinsic properties of the ceramic |
| 3. | Maintain open communication for optimization |
| Results |
 | Replacement material does not chip. Unscheduled downtime eliminated |
| | Wear of ceramic rolls after two weeks less than .0002” (5 microns) |
| | Production rate raised to over 144 miles (230km) of tubing per machine per day |
Application |
| Regrind service on mill rolls |
| Service Conditions |
| 1. | High temperature guide rolls for non-ferrous rod mill |
| 2. | Guiding of copper rod from head end to back end of mill |
| 3. | Mill guides have large adjustment range |
| Problems |
| 1. | Rolls wear in contact with hot metal |
| 2. | New rolls are expensive |
| 3. | Metal rolls cannot be used due to contamination of product |
| Solution |
| 1. | Offered to regrind existing rolls to remove galling, adhered metal and worn areas |
| 2. | Mill guides easily adjusted to accommodate resized rolls |
| Results |
| | Saved customer significant money and time |
| | Fast turnaround provided. Far faster than new roll fabrication. |
| | Critical geometries were recovered |
