5 Reasons Why Your Business Needs Copper Grinding Machine？

Providing in-house grinding is a benefit to both the machine shop doing the grinding as well as its customers. The in-house process saves time and money, and helps a shop create higher quality parts.

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Ripley Machine and Tool Inc. (Ripley, New York), has had in-house grinding capabilities since the s. In , when President Andy Reinwald's grandfather purchased the company, grinding for other regional machine shops was a larger portion of what the company offered to its customers than what it does today. Reinwald explains that back then there was a big demand for the service because the barstock material quality was not as good as it is today, and the machines were not able to hold sizes (tolerances) as well as they do currently.

I recently talked to Reinwald, a Production Machining Emerging Leader, to understand more about the shop's' in-house grinding processes and discover what the biggest advantages are. Here are what he says are the top five advantages:

1 ' Offering a service to other shops, while also making grinding a profit center.

Although grinding as a service to others might have been more popular in , Ripley Machine still has about 12 regional customers for which it grinds parts. But the company also specializes in CNC milling and turning, and recently bought its first Swiss-type turning center a little more than a year ago. The company has 10 grinding machines to perform internal, centerless barstock, through-feed centerless, in-feed centerless, and center grinding.

Ripley Machine can grind customer-supplied material or use one of its qualified vendors to purchase and supply the material. It has experience grinding various materials, including tool steel, stainless steel, aluminum, Hastelloy, brass, copper and more. 

For centerless grinding, the shop is capable of grinding bars up to 1 inch diameter at lengths up to 14 feet long. For high production jobs for through-feed centerless grinding, the company uses automatic feeders and air gaging.  

For internal grinding, the company is able to grind straight or taper bores and can grind parts with a bore diameter between 0.625 inch and 9 inches with a length up to 7 inches.

2 ' Faster access to precision ground barstock.

Ripley Machine's customers that take advantage of its in-house grinding capabilities save money buying ground stock from Ripley Machine because the shop can do the process cheaper and, therefore, charge less than a mill would. Also, instead of waiting one to two weeks for barstock to be ground and delivered from a mill, it typically takes Ripley only a couple days to precision grind stock in-house.

Now that Ripley Machine, a Modern Machine Shop Top Shops winner, is doing some Swiss machining, having easier access to precision ground barstock has been invaluable. 'It is significantly quicker because we can have ground material set up in one day,' Reinwald explains. 'One of our material suppliers can typically have it to us by the next day. And as soon as it gets here, we have our grinder ready to go. We eliminate so many middlemen and gaps.' He adds that it is a lot less expensive to precision grind his own stock because he can control the cost.

3 ' Production on the Swiss-type machine starts sooner.

Having in-house grinding also means having the ability to use the grinders more efficiently to get the ground barstock shipped out sooner. When ground barstock is purchased from a mill, customers normally must wait for the entire order to be ground and shipped. 'We can get one bar ground, get it over to our Swiss setup guys and have our Swiss team work on the initial parts and get the setup running smoothly,' Reinwald says. 'Simultaneously, the grinder is still running the rest of the material for the production order.'

4 ' Improving size, tolerance and finish of barstock prior to machining.

The quality of bar that is put into a Swiss-type machine is the same quality of part that will come out of it. Reinwald says sometimes stock material that has been purchased from the mill will not meet certain finish and size requirements for a job on a Swiss machine. Therefore, having the ability to create ground bar to the size and finish necessary can be the only way to satisfy a customer.

'One shop we work with needed to have a bar a certain size, and they needed it ground down to fit into a collet rather than buying a guide bushing and at least one collet, maybe two,' Reinwald explains. 'Their potential costs would have been at least a couple hundred bucks and whatever lead time. For us, though, it was a small bar that was less than a hundred dollars to grind.'

5 ' Creating better surface finishes than what is possible by turning alone.

When parts that have been machined on a lathe or Swiss or even on one of Ripley's mills do not meet surface finish requirements or are perhaps marred from workholding, it is possible to grind the part after machining to meet finish requirements. Reinwald says the company might use one of its grinders to take off 5 tenths to a thousandth of an inch in total diameter on a part to ensure a good finish.

He adds his shop might grind a round part when both ends need to be machined.

When buyers purchase a machine, before using they need time to get familiar with it for a complete understanding, which will decrease the machine failure rate and save a lot of time in the future. What's more, reasonable maintenance methods are also important, the right and appropriate maintenance can extend its service life effectively and make sure it can process waste wires at a high speed and get high-quality copper products successfully. We write this article for you to help you grasp all the relevant information better and faster.

Troubleshoot'' 25 Tips to Make You Succeed in Copper Wire Granulator Business

If granulator machines can't operate at their optimal performance or have some malfunctions, the reasons may be complex due to the unique structures of different machine parts. But we are capable of dealing with these troubles with our rich industry experience. 

Now, we list 25 tips from 6 aspects to help you understand granulator machines in the market and provide solutions to all the problems that customers may encounter from installation to use.

25 Tips to Make Copper Wire Granulator Reach Best

Improper operation

1. Feeding too many waste wires will cause the main shredder to get stuck. If you meet this problem, you can shut it down immediately and cut off the main power supply, then open the upper cover, and remove the jammed waste wires.

2. If waste wires are covered with water, or oil, or wrapped with electrical tape, they cannot be separated directly. In these cases, you can wipe them, clean the oil on their surface and remove the wrapped electrical tape, but for different kinds of cables need to be different methods to process:

• For oil cables, you can use our water granulator machine to process them and add the solvent into the water.
• For car cables and cable with tapes, you can add some talcum powder when you process or before recycling.

3. Screws are mostly used in granulator machines production and play an important role in connection, so every screw must be tightened greatly. If you run the machine without tightening the screws enough, it will be easily damaged to the machine itself.

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4. Check the support plates on both sides of the air separator system regularly and replace them promptly if there are any cracks or breaks.

5. The machine needs about 20 minutes of break to be ensured after every 4 hours of work, or else it will be harmful to the machine.

6. Check whether the direction of spindle rotation is consistent with the direction shown on the protective cover. If it is wrong, you should make a change.

7. Try not to tie the dust bag mouth tightly and leave a bowl-sized space for exhaust.

Abnormalities in the copper outlet and plastic outlet

8. If no copper particles come out of the copper outlet, speed up the vibrating table and reduce wind force.

9. If plastic particles come out of the copper outlet, slow down the vibrating table and increase wind force.

10. If no plastic particles come out of the plastic outlet, slow down the vibrating table and increase the wind force.

11. If copper particles come out of the plastic outlet, speed up the vibrating table and reduce the wind force.

12. The copper outlet of the air separator is equipped with a press plate, which is adjustable in height. The lower the pressing plate is, the harder it is for the copper product to come out. Generally, the pressing plate is about 3cm away over the air separator sieve surface.

Bad separation effect

The reasons for the poor separation effect can be analyzed depending mainly on three aspects: the situation of waste wires, blades, and crusher sieve or the operation.

13. If the interior of the waste wire contains hemp rope, fiber, aluminum, platinum and other substances, which will affect the separation effect.

14. If the blades are severely worn or not sharp enough, some of the waste wires cannot be completely cut off but are pulled off. The length of them is relatively long which is not conducive to subsequent separation therefore affects the final product, so you need to sharpening blades.

Shredder blades as follows:

16. Improper installation of the blade will slow down the speed of cutting as well as affect the separation result.

17. The machine should be kept in level ground which means there can't be any shaking during operation. The machine shaking will disturb the vibration generated by the air separator system and vibrating table which is the main basis for separating copper from plastic skins. If the shaking is caused by a gap between the machine chassis and the ground, you can insert iron pieces into until the whole machine can work stable.

'The clean methods of the machine

18. The air inlet filter and separation sieve must be cleaned in time. Use an air gun to clean the debris inside air separator sieves regularly to ensure the normal separation of the machine separation system, blockage of the machine will affect the separation effect. When cleaning, you need to remove them first and then put the high-pressure air gun against the screen surface to blow away the blocked dust from the front to the back. If there are fine wires stuck in the mesh screen, you can use a scraper to remove them.

19. Dust collection bags also need to be cleaned in time to prevent the bags from clogging and affecting exhaust. You can open the dust collection box first and then hit it with a stick with appropriate force. If the force is too small, it will have no cleaning effect. If the force is too strong, it may damage the bag.

''Machine Maintenance

20. The main bearings of the crusher, separator, and electrostatic separator should be filled with high-pressure and high-temperature resistant butter every 3 months.

21. The main bearing of the separator and the eccentric wheel on both sides should be filled with high-pressure and high-temperature butter every 4 months.

22. The front and back sides of the insulation board of the electric wire rack should be cleaned with an air gun one time every 10 days and the discharge wire should be wiped with a cloth once a month.

''Safe operation

23. When feeding, be careful not to let the waste wires wrap around any part of the human body.

24. Spiral blades rotate at high speed inside the winch cage mouth, so do not put any part of your body into it.

Your Best Choice - BSGH Granulator

When you operate the machine, you can ask our sales staff, we have experience in this field for more than 25years, you can take more videos for us and show us even if you use the machine best, we also can check whether can adjust for you to the better effect, bigger processing capacity.

When you use BSGH Granulators, you will have less troubles and have a better experience and pleasant journey for making more money.

Conclusion

This article acts as a communication link and bridge between products and customers. We hope it can help customers better understand product functions, performance, and other related information. Secondly, this article enables customers to use and operate the product correctly and avoid problems and losses caused by misunderstanding or incorrect operation. If you want to know more information, you can contact our staff at any time.

Want more information on Copper Grinding Machine? Feel free to contact us.