When “Close Enough” Just Won’t Cut It: A Case Study

For precision rotary die cutters, GMN Bearing USA’s angular contact bearings boost output, quality & offer longer part life cycles

GMN Bearing USA is known for our finely crafted, German-engineered precision bearings—truly the definition of industrial motion in its purest form. Our high performing parts find their place in diverse applications, including precision rotary die cutting equipment. These industrial processing machines operate at high speeds and require the tightest of tolerances, sometimes operating with gaps as small as just a few microns.

This intricate production process includes high volume materials, manufacturing multi-step items, which includes things like “kiss cutting”, multi-level cutting, perforations, zoned adhesion and scoring often linked with personal care products and items such as foil, tapes and non-woven materials.

This means that only the best will do. Enter GMN bearings.

Overview:

The Problem

Our customer, who repairs and services rotary die cutting equipment for an American-based consumer goods manufacturer, was having a very short and costly MTBR (Mean Time Between ReBuilds/Repair) for their RDC (Rotary Die Cutter) equipment. It was a known issue that the reduced MTBR was hindering profits, but the customer felt it could be managed.

That is until one day, when our repair customer realized a quick delivery of bearings became critical after their customer’s equipment had been pushed past its normal rebuild timeframe.

GMN Bearing USA rushed the replacement parts to our customer, and they were grateful for the stock and delivery. However, when the end user was examining the anvil on the rotary die cutter the next morning, they realized how far they pushed the equipment. It was ruined. Now, instead of just paying for a rebuild, they had to have their anvil refinished as well.

The Solution

After hearing about the end user’s plight, GMN Bearing USA engineers stepped in to support their efforts to prevent future occurrences of unexpected downtimes. After a few lengthy bearing examinations and consultative conference calls, a key aspect was found: There was consistent orbital and cyclical loading appearing on the bearing outer races.

The preload of the bearings and overall rigidity of the system could be increased to hold the equipment even tighter in geometric center. Sub 5 micron TIR (Total Indicated Runout) was going to be the new installed target. Increasing rigidity supported rotation around the geometric center and reduced overall bearing load from the heavy anvil. With this heavy equipment, combined with high-speed rotation, very tight balancing and controlling very tight TIR to geometric center, it’s paramount for an acceptable MTBR.

This reduced radial load and tighter rotation increased bearing life, increased MTBR, and increased profitability!

GMN Bearing USA is now evaluating our customer’s entire production system, from rollers to dies to anvils. We have already seen multiple success’ and only anticipate more.

If you feel you’re not getting a good bearing life or acceptable MTBR, contact GMN Bearing USA engineers today for a free consultative analysis.

What can you expect from GMN precision angular contact bearings for rotary die cutters?

GMN S Series angular contact bearings offer:

• Up to +20%-30% increased operating capacity (compared with non-angular contact bearing designs),
• GMN bearings = ABEC 7 standards (P4+) with ABEC 9 (P2) running accuracy, 
• Greater production accuracy with ≤5 microns in multiple runouts, and
• Longer bearing part life compared with non-angular contact bearings.

Key considerations for our customer when it comes to rotary die cutting and how GMN bearings come into play:

• Materials. Intricately constructed layers that require perforation and cuts can benefit from precision bearings.
• High production volume. Rotary die cutting takes advantage of higher speeds and reduced time per part, but requires exactness in performance, time after time. GMN bearings operate at incredible speeds without compromising reliability.
• Part complexity. For applications for personal healthcare products, rotary die cut parts require a combination of steps such as sheeting, scoring, slitting, etc. This requires sophisticated web tensions for precise cutting pressures with maximum speed. GMN bearings can hold tight tolerances over long periods of time, allowing for uniform, repeatable results.

Other rotary die cut materials that benefit from our precision angular contact bearings include:

• Plastic film
• Nylon
• Felt
• Abrasives
• Foam tapes
• Nonwoven fabrics
• Pressure sensitive adhesives
• Foils

Our bearings are perfect for new equipment designs and can also be drop-in replacements for your existing machine bearings.

Learn more about our S Series Angular Contact Bearings for Rotary Die Cutting Equipment and contact us today for an application evaluation.

S Series Angular Contact Bearings for Rotary Die Cutting Equipment

Slug	Part Number	Size	Series	d	D	B	dm	DW	Z	d1	D1	D2	r1,2	r3,4	ra max	rb max	da, b min	Da, b max	dT	m	α0	C	C0	C0 HY	noil	ngrease	Fv	Cax	Fv	Cax	Fv	Cax	Ff
bb-s-61910-c-ta-angular-contact-bearing	S 61910 C TA	61910	S	50	72	12	61	6.35	21	56.8	65.2	67.2	0.6	0.3	0.6	0.15	55	67.5	58.9	0.129	15	15400	14500	10200	28000	21000	80	50	230	81	460	115	395
bb-s-6010-c-ta-angular-contact-bearing	S 6010 C TA	6010	S	50	80	16	65	8.731	19	59.7	70	73.6	1	0.6	1	0.3	56	74	62.5	0.256	15	28000	24300	171000	26000	19500	140	64	420	110	840	160	715
bb-s-6210-c-ta-angular-contact-bearing	S 6210 C TA	6210	S	50	90	20	70	12.7	15	62.5	76.9	82.7	1.1	0.6	1	0.6	58	82	66.7	0.486	15	47500	37000	26000	24500	18500	240	75	720	125	1440	178	1220
bb-s-61911-c-ta-angular-contact-bearing	S 61911 C TA	61911	S	55	80	13	67.5	7.144	21	63.1	71.9	74.5	1	0.3	0.6	0.3	60	75	65.4	0.181	15	18400	17100	12100	25000	18500	90	52	280	87	560	122	470
bb-s-6011-c-ta-angular-contact-bearing	S 6011 C TA	6011	S	55	90	18	72.5	9.525	20	66.8	78.2	81.9	1.1	1	1.1	0.6	62	83	69.8	0.374	15	32500	29500	20500	23500	17500	160	69	490	115	980	163	830
bb-s-6211-c-ta-angular-contact-bearing	S 6211 C TA	6211	S	55	100	21	77.5	14.288	15	69	85.8	91.6	1.5	1	1.5	1	64	91	73.8	0.621	15	58000	46000	32500	22000	16500	300	83	900	139	1800	199	1480
bb-s-61912-c-ta-angular-contact-bearing	S 61912 C TA	61912	S	60	85	13	72.5	7.144	23	68.1	76.9	79.5	1	0.3	0.6	0.3	65	80	70.4	0.195	15	19200	19000	13300	23500	17500	100	58	300	94	600	132	490
bb-s-6012-c-ta-angular-contact-bearing	S 6012 C TA	6012	S	60	95	18	77.5	9.525	22	71.9	83.2	87	1.1	1	1.1	0.6	67	88	74.9	0.406	15	34000	32500	22800	22000	16500	170	75	515	124	1030	175	870
bb-s-6212-c-ta-angular-contact-bearing	S 6212 C TA	6212	S	60	110	22	85	15.875	15	76	95.5	101.4	1.5	1	1.5	1	70	101	81.5	0.795	15	70000	56500	40000	20000	15000	350	90	1000	146	2100	213	1790
bb-s-61913-c-ta-angular-contact-bearing	S 61913 C TA	61913	S	65	90	13	77.5	7.144	24	73.1	81.9	84.5	1	0.3	0.6	0.3	70	85	75.4	0.207	15	19500	20000	14000	22000	16500	100	59	300	96	600	135	500
bb-s-6013-c-ta-angular-contact-bearing	S 6013 C TA	6013	S	65	100	18	82.5	9.525	23	76.9	88.2	92	1.1	1	1.1	0.6	72	93	79.9	0.431	15	34500	34500	24100	20500	15500	175	78	525	128	1050	181	880
bb-s-6213-c-ta-angular-contact-bearing	S 6213 C TA	6213	S	65	120	23	92.5	15.875	16	82.8	102.3	108.5	1.5	1.1	1.5	1.1	75	110	88.3	1.008	15	72500	61500	43500	18500	14000	370	96	1110	158	2220	225	1850
bb-s-61914-c-ta-angular-contact-bearing	S 61914 C TA	61914	S	70	100	16	85	7.938	24	80.1	89.9	92.7	1	0.3	0.6	0.3	76	94.5	82.6	0.346	15	24400	26000	18200	20000	15000	130	69	370	111	740	156	625
bb-s-6014-c-ta-angular-contact-bearing	S 6014 C TA	6014	S	70	110	20	90	11.906	21	82.6	97.4	101.7	1.1	1	1.1	0.6	77	102	86.6	0.593	15	48500	46000	32500	19000	14000	240	85	700	140	1400	200	1240
bb-s-61915-c-ta-angular-contact-bearing	S 61915 C TA	61915	S	75	105	16	90	8.731	25	84.7	95.3	98.8	0.6	0.3	0.6	0.3	81	99.5	87.5	0.35	15	29500	31000	21600	19000	14000	150	75	440	120	890	169	760
bb-s-6015-c-ta-angular-contact-bearing	S 6015 C TA	6015	S	75	115	20	95	11.906	22	87.8	102.2	107	1.1	0.6	1.1	0.6	82	107	91.7	0.64	15	49500	48500	34000	18000	13500	250	91	760	148	1510	208	1270
bb-s-61916-c-ta-angular-contact-bearing	S 61916 C TA	61916	S	80	110	16	95	9.525	25	89.4	100.8	104.6	0.6	0.3	0.6	0.3	86	104	92.4	0.37	15	35500	38500	27000	18000	13500	180	84	540	136	1080	192	910
bb-s-6016-c-ta-angular-contact-bearing	S 6016 C TA	6016	S	80	125	22	102.5	13.494	20	94.3	110.7	116.1	1.1	0.6	1.1	0.6	88	117	98.7	0.84	15	60000	58000	41000	16500	12500	310	98	920	159	1830	224	1540
bb-s-61917-c-ta-angular-contact-bearing	S 61917 C TA	61917	S	85	120	18	102.5	10.319	25	96.2	108.8	112.9	0.6	0.6	0.6	0.6	92	114	99.5	0.54	15	40000	43000	30500	16500	12500	200	87	610	142	1220	198	1020
bb-s-6017-c-ta-angular-contact-bearing	S 6017 C TA	6017	S	85	130	22	107.5	13.494	21	99.3	115.7	121.1	1.1	0.6	1.1	0.6	93	122	103.7	0.89	15	61500	61500	43500	16000	12000	310	101	940	165	1880	233	1570
bb-s-61918-c-ta-angular-contact-bearing	S 61918 C TA	61918	S	90	125	18	107.5	10.319	26	101.2	113.8	117.9	0.6	0.6	0.6	0.6	97	119	104.5	0.56	15	40500	45000	31500	16000	12000	210	91	620	146	1240	204	1040
bb-s-6018-c-ta-angular-contact-bearing	S 6018 C TA	6018	S	90	140	24	115	15.081	20	105.8	124.2	130.1	1.5	0.6	1.5	0.6	100	131	110.7	1.15	15	74500	74000	52000	15000	11000	380	110	1130	179	2270	255	1900
bb-s-61919-c-ta-angular-contact-bearing	S 61919 C TA	61919	S	95	130	18	112.5	10.319	27	106.2	118.8	122.9	0.6	0.6	0.6	0.6	102	124	109.5	0.59	15	41000	47000	33000	15000	11000	210	93	630	150	1250	209	1050
bb-s-6019-c-ta-angular-contact-bearing	S 6019 C TA	6019	S	95	145	24	120	15.081	21	110.8	129.2	135.1	1.5	0.6	1.5	0.6	105	136	115.7	1.2	15	77000	79000	55000	14000	10500	390	114	1160	186	2330	265	1970
bb-s-61920-c-ta-angular-contact-bearing	S 61920 C TA	61920	S	100	140	20	120	11.906	25	112.8	127.2	132	0.6	0.6	0.6	0.6	107	133	116.5	0.8	15	51500	57000	40500	14000	10500	260	100	790	162	1570	226	1320
bb-s-6020-c-ta-angular-contact-bearing	S 6020 C TA	6020	S	100	150	24	125	15.081	22	115.8	134.2	140.1	1.5	0.6	1.5	0.6	110	141	120.7	1.25	15	78000	83000	58000	13500	10000	400	118	1190	193	2380	275	1990
bb-s-61921-c-ta-angular-contact-bearing	S 61921 C TA	61921	S	105	145	20	125	11.906	26	117.8	132.2	137	0.6	0.6	0.6	0.6	112	138	121.5	0.83	15	52500	60000	42000	13500	10000	270	103	800	166	1600	232	1340
bb-s-6021-c-ta-angular-contact-bearing	S 6021 C TA	6021	S	105	160	26	132.5	15.875	22	122.8	142.2	148.4	2	1	2	1	116	150	127.9	1.59	15	86000	92000	64500	13000	9800	440	125	1310	203	2610	285	2200
bb-s-61922-c-ta-angular-contact-bearing	S 61922 C TA	61922	S	110	150	20	130	11.906	27	122.8	137.2	142	0.6	0.6	0.6	0.6	117	143	126.5	0.86	15	53500	62500	44000	13000	9800	270	106	810	170	1620	238	1370
bb-s-6022-c-ta-angular-contact-bearing	S 6022 C TA	6022	S	110	170	28	140	17.462	21	129.4	150.6	157.5	2	1	2	1	121	159	135	1.98	15	99000	105000	73500	12000	9000	500	130	1510	212	3020	300	2550
bb-s-61924-c-ta-angular-contact-bearing	S 61924 C TA	61924	S	120	165	22	142.5	13.494	27	134.3	150.7	156	0.6	0.6	0.6	0.6	128	157	138.5	1.18	15	67500	80000	56000	12000	9000	340	120	1030	195	2060	275	1730
bb-s-6024-c-ta-angular-contact-bearing	S 6024 C TA	6024	S	120	180	28	150	17.462	23	139.4	160.6	167.5	2	1	2	1	131	169	145	2.13	15	104000	116000	82000	11500	8600	530	140	1580	227	3170	320	2700