We have a very diverse range of equipment and experience in this area.
Equipment and experience include:
- Metal disintegration machining
- Inductor technology (This is a flameless heat system that can turn metal red hot in seconds)
- Extractors, left hand drill bits and more
JE Mechanical specializes in safe removal of broken taps, ez-outs, drill bits, bolts, studs and fasteners of any kind. Our process does not damage the existing hole, bore or threads with heat. We are a mobile service and in most cases repair the part or parts without disassembly or removal of equipment from its work area, repairs can be done on the spot.
The process we use is known as MDM "Metal Disintegration Machining" or Spark Erosion. This process is similar to EDM "Electro discharge Machining". Unlike EDM, MDM has better portability and is much more cost effective for field applications and just repairing the parts.
MDM can plunge or punch round diameters or holes from .020 to .500. And square holes for ¼", 3/8" and ½".
Metals or materials that MDM can cut through include: Carbon Steels, Stainless Steels, Titanium, High Speed Tool Steel, HSS, Cast Iron, Iron, Clad Carbon Steel, Carbides, Monels or Nickel Alloys, Inconels, Manganese.
The MDM machine uses a constant power source much like an arc welder. The electrode made from Graphite or Molybdenum vibrates up and down at 60 times a second. Each time the electrode strike the work piece the arc super heats the metal causing instant solidification. One the electrode returns the arc is broken and the coolant cools the metal causing the metal to re-solidify. The coolant running constant throughout the entire process washes away the particles of disintegrated metal, and does not allow any heat to build up in the part.
Examples of uses for Electronic Disintegration:
- Rock bit salvaging, Removal of Carbide inserts
- Metallurgical Core Sampling
- Large pin removal (Example: Paper mills, Air Craft & Heavy equipment)
- Removal of broken taps
- Removal of broken drill bits
- Removal of broken E-Z Outs
- Removal of broken reamers
- Removal of broken taps
- Removal of broken end mills
- Removal of broken bolts
- Removal of broken studs
- Removal of broken screws
- Cutting & gouging
Electronic Disintegration is frequently used in the following applications
- Civil engineering
- Food processing facilities
- Firearm repair
- Heavy equipment repair
- Utilities companies
- Tool & equipment rental companies
- Metalurgical core sampling
- Off shore oil industry
- Power generation
- Rail roads
- Mining companies
- Water well drilling
Note: When removing tooling and hardware size (such as diameter) does not matter. On large bolts for example, a series of cuts or passes may need to be performed to reach the desired out come.
In what types of situations may Electronic Disintegration may be an option or last resort?
- In removal of rusted or seized pins, studs, screws, bolt, etc.
- Removing broken tooling such as taps and drill bits
- If the part that is in repair can be damaged by heat or the treads can be damaged by heat. Example: A broken stud or tap in an aluminum cylinder head of an engine
- If equipment down time must be minimized
- Replacing the part is too costly
- Replacement parts are not available
- Unacceptable lead time to get replacement part
When does Electronic Disintegration make sense?
Example situations where metal disintegration makes economical sense or in some cases may be the only option.
- In water depths that are too great for a torch. Because water pressure will compress gases torches will only operate up to a certain depth depending on salinity and altitude. Water pressure will not affect the arc so this allows MDM to operate to depths well beyond 60 feet.
- In most cases disintegration is much faster and minimizes equipment down time compared to more familiar methods of removing broken tooling or fasteners.
- Where the material, tool, fastener or pin is hardened or is made of a material harder than a cutting tool such as a drill bit or end mill. Thus does not allow for drilling or machining.
- Confined areas where a Mag-Base drill or regular drill cannot be used due to space constraints.
- Areas where cutting with a torch or flame would be hazardous.
- If the part itself could be damaged by heat.
- If the risk of damaging the original bore or threads must be saved to ensure structural or strength requirements.