Production Details

There are many details regarding the processing and production of stone materials.  Below we have some parameters and guidelines for you to consider.  

Tooling Information

 

What you'll need:

Finger bits

Core bits

ISO 40 cones (hold tooling, bits, and wheels)

Calibrating wheel (evens out the surface)

Profile tool set (7 wheels - 4 stone, 3 resin polishing)

 

Profile Considerations:

Profile sets cost $2,000 - $3,500

Profile sizes: 60mm or 120mm diameter

Profile heights: 2cm, 3cm, or 4cm

Each set consists of:

4 diamond bits and 3 polishing bits

Regular speed or hyper speed sets are available

 

Tool Durability / Life span:

Some expected guidelines are below regarding durability/life span:

 

#1 Diamond tool:  4,000 - 6,000 linear feet

#2 Diamond tool: 12,000 - 16,000 linear feet

#3 Diamond tool: 12,000 - 16,000 linear feet

#4 Diamond tool: 12,000 - 16,000 linear feet

#5 Polishing tool: 1,000 - 1,500 linear feet

#6 Polishing tool: 1,000 - 1,500 linear feet

#7 Polishing tool: 1,000 - 1,500 linear feet

 

Finger bits last approximately 300 - 600 linear feet

Core bits last for 200 - 300 holes

 

Variations in wear are the result of how much material the bit is required to remove as well as differences in bit density.  The lifespan of the #1 diamond tool can be extended by dressing the wheel periodically.  This in turn extends the life of all the other bits as well.

Shop Requirements



Water:

Fresh water is required for inside the spindle.

Recycled water can be used for outside the spindle.

Water use:  Approx. 5-7 gallons per minute total usage.  Fresh water requirement is about 10% of this amount.  With recycling the water, figure about 200 - 300 gallons per day of fresh water use with 8 hours of consistent machine use and a good recycling system.

 

Water recycling - there are two main ports that face towards the back of the machine to drain the water.  A variety of water recycling systems can be employed to reduce water usage.  We have some very compact and powerful water cleaning (solids removal) and recycling systems available here at Eagle Rock.  If you need a system to clean large amounts of water quickly, check out the Eagle Rock Aqua line here.

 

Air:

120 PSI needed, low volume

Used for tool changer 

 

Electric Power:

Uses: 3 Phase, 380 V

Transformer ships with the machine

Accepts 208V, 220V or 240V - 3 Phase power

 

Physical Space:

Please refer to the comparison page (download) to receive full details of all three machines in a side-by-side chart.

 

Overall machine dimensions:

 

 

Vision2: D:87"  H:85"  W:172"

 

Vision3: D:125"  H:94.5"  W:213"

 

 

 

Manual vs. CNC comparison



The following information has been gathered from a number of sources.  These numbers can be used to make a reasonable estimation of cost savings from automated CNC equipment versus manual fabrication.

 

Manual Fabrication:

Tooling cost per lineal foot: $3.00

Approximate production labor cost is calculated at $15 per hour with a 3 foot per hour production

=$5 manual labor cost per lineal foot

TOTAL manual cost=$3 + $5=$8 per lineal foot

 

Manual cost: $8-$9 per lineal foot

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CNC Fabrication:

Tooling cost per lineal foot: $1.00 (wheels and bits)

Approximate production cost with a machine operator paid at $20 per hour with a 15 foot per hour production rate=$1.33 CNC cost per lineal foot

TOTAL CNC cost=$1 + $1.33=$2.33 per lineal foot

 

CNC cost: $2.33 per lineal foot

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For additional information about calculating manual labor vs CNC production costs, please contact us and we will send you an Excel spreadsheet to help you determine the appropriate comparison for your shop as well as the approximate number of months when your machine will pay for itself.

© 2014 Eagle Rock Products