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

You are here: Home / Articles / 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

anvil and roller
Anvil & Roller

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

SlugPart NumberSizeSeriesdDBdmDWZd1D1D2r1,2r3,4ra maxrb maxda, b minDa, b maxdTmα0CC0C0 HYnoilngreaseFvCaxFvCaxFvCaxFf
bb-s-61910-c-ta-angular-contact-bearingS 61910 C TA61910S507212616.352156.865.267.20.60.30.60.155567.558.90.129151540014500102002800021000805023081460115395
bb-s-6010-c-ta-angular-contact-bearingS 6010 C TA6010S508016658.7311959.77073.610.610.3567462.50.256152800024300171000260001950014064420110840160715
bb-s-6210-c-ta-angular-contact-bearingS 6210 C TA6210S5090207012.71562.576.982.71.10.610.6588266.70.4861547500370002600024500185002407572012514401781220
bb-s-61911-c-ta-angular-contact-bearingS 61911 C TA61911S55801367.57.1442163.171.974.510.30.60.3607565.40.181151840017100121002500018500905228087560122470
bb-s-6011-c-ta-angular-contact-bearingS 6011 C TA6011S55901872.59.5252066.878.281.91.111.10.6628369.80.37415325002950020500235001750016069490115980163830
bb-s-6211-c-ta-angular-contact-bearingS 6211 C TA6211S551002177.514.288156985.891.61.511.51649173.80.6211558000460003250022000165003008390013918001991480
bb-s-61912-c-ta-angular-contact-bearingS 61912 C TA61912S60851372.57.1442368.176.979.510.30.60.3658070.40.1951519200190001330023500175001005830094600132490
bb-s-6012-c-ta-angular-contact-bearingS 6012 C TA6012S60951877.59.5252271.983.2871.111.10.6678874.90.406153400032500228002200016500170755151241030175870
bb-s-6212-c-ta-angular-contact-bearingS 6212 C TA6212S60110228515.875157695.5101.41.511.517010181.50.79515700005650040000200001500035090100014621002131790
bb-s-61913-c-ta-angular-contact-bearingS 61913 C TA61913S65901377.57.1442473.181.984.510.30.60.3708575.40.2071519500200001400022000165001005930096600135500
bb-s-6013-c-ta-angular-contact-bearingS 6013 C TA6013S651001882.59.5252376.988.2921.111.10.6729379.90.431153450034500241002050015500175785251281050181880
bb-s-6213-c-ta-angular-contact-bearingS 6213 C TA6213S651202392.515.8751682.8102.3108.51.51.11.51.17511088.31.00815725006150043500185001400037096111015822202251850
bb-s-61914-c-ta-angular-contact-bearingS 61914 C TA61914S7010016857.9382480.189.992.710.30.60.37694.582.60.34615244002600018200200001500013069370111740156625
bb-s-6014-c-ta-angular-contact-bearingS 6014 C TA6014S70110209011.9062182.697.4101.71.111.10.67710286.60.5931548500460003250019000140002408570014014002001240
bb-s-61915-c-ta-angular-contact-bearingS 61915 C TA61915S7510516908.7312584.795.398.80.60.30.60.38199.587.50.3515295003100021600190001400015075440120890169760
bb-s-6015-c-ta-angular-contact-bearingS 6015 C TA6015S75115209511.9062287.8102.21071.10.61.10.68210791.70.641549500485003400018000135002509176014815102081270
bb-s-61916-c-ta-angular-contact-bearingS 61916 C TA61916S8011016959.5252589.4100.8104.60.60.30.60.38610492.40.37153550038500270001800013500180845401361080192910
bb-s-6016-c-ta-angular-contact-bearingS 6016 C TA6016S8012522102.513.4942094.3110.7116.11.10.61.10.68811798.70.841560000580004100016500125003109892015918302241540
bb-s-61917-c-ta-angular-contact-bearingS 61917 C TA61917S8512018102.510.3192596.2108.8112.90.60.60.60.69211499.50.541540000430003050016500125002008761014212201981020
bb-s-6017-c-ta-angular-contact-bearingS 6017 C TA6017S8513022107.513.4942199.3115.7121.11.10.61.10.693122103.70.8915615006150043500160001200031010194016518802331570
bb-s-61918-c-ta-angular-contact-bearingS 61918 C TA61918S9012518107.510.31926101.2113.8117.90.60.60.60.697119104.50.561540500450003150016000120002109162014612402041040
bb-s-6018-c-ta-angular-contact-bearingS 6018 C TA6018S901402411515.08120105.8124.2130.11.50.61.50.6100131110.71.15157450074000520001500011000380110113017922702551900
bb-s-61919-c-ta-angular-contact-bearingS 61919 C TA61919S9513018112.510.31927106.2118.8122.90.60.60.60.6102124109.50.591541000470003300015000110002109363015012502091050
bb-s-6019-c-ta-angular-contact-bearingS 6019 C TA6019S951452412015.08121110.8129.2135.11.50.61.50.6105136115.71.2157700079000550001400010500390114116018623302651970
bb-s-61920-c-ta-angular-contact-bearingS 61920 C TA61920S1001402012011.90625112.8127.21320.60.60.60.6107133116.50.815515005700040500140001050026010079016215702261320
bb-s-6020-c-ta-angular-contact-bearingS 6020 C TA6020S1001502412515.08122115.8134.2140.11.50.61.50.6110141120.71.25157800083000580001350010000400118119019323802751990
bb-s-61921-c-ta-angular-contact-bearingS 61921 C TA61921S1051452012511.90626117.8132.21370.60.60.60.6112138121.50.8315525006000042000135001000027010380016616002321340
bb-s-6021-c-ta-angular-contact-bearingS 6021 C TA6021S10516026132.515.87522122.8142.2148.42121116150127.91.5915860009200064500130009800440125131020326102852200
bb-s-61922-c-ta-angular-contact-bearingS 61922 C TA61922S1101502013011.90627122.8137.21420.60.60.60.6117143126.50.861553500625004400013000980027010681017016202381370
bb-s-6022-c-ta-angular-contact-bearingS 6022 C TA6022S1101702814017.46221129.4150.6157.521211211591351.98159900010500073500120009000500130151021230203002550
bb-s-61924-c-ta-angular-contact-bearingS 61924 C TA61924S12016522142.513.49427134.3150.71560.60.60.60.6128157138.51.1815675008000056000120009000340120103019520602751730
bb-s-6024-c-ta-angular-contact-bearingS 6024 C TA6024S1201802815017.46223139.4160.6167.521211311691452.131510400011600082000115008600530140158022731703202700

Category iconArticles,  Case Studies Tag iconAngular Contact Bearings,  Bearings

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