January 2010- It takes a lot to build an iconic brand. Harley-Davidson is synonymous with denim, leather and the open road, but the company’s much-sought-after motorcycles can’t get by on name alone. They have to be built tough and demonstrate high, reliable performance.
Because of this, every component of the bikes must be as high quality as possible, even down to the nuts, bolts and washers.
JBA Precision, Manitowoc, Wis., is a one-man fabricating and machine shop that supplies groupings of washers for a customer that manufactures fairings for the motorcycle industry. Thus, JBA’s washers are used in the motorcycle aftermarket, as they connect the motorcycle fairing and windshield to the bike frame. Last year, JBA produced between 5,000 and 8,000 parts for the motorcycle aftermarket.
"The washers are on the exterior, so they have to look good because they are going to be both functional and cosmetic," said Jeffrey Kopidlansky, owner-operator of JBA Precision.
Fabricating the washers requires precise and efficient tooling processes, and to enhance its overall shop performance, JBA began using Prodec 303 stainless bar material in 1-in. form supplied by Rolled Alloys, Streamwood, Ill. Prodec is a proprietary grade from Outokumpu, Espoo, Finland, specifically its long products facility in Richburg, S.C.
"By the second run with Prodec 303, I noticed that I was getting up to 500 cuts, and normally I’d change the tool tip after 100 to 300 cuts," said Kopidlansky. "And the finish maintained for a longer time, even with a duller tool."
Kopidlansky added that since implementing Prodec 303, his tools are lasting six months or longer, and his drill speeds have increased.
Special steel
The Prodec line of material was developed by Outokumpu more than 30 years ago, and the 303 material became available in 2000 and is specifically geared toward increasing its machinability for customers using 303. It’s available in bar and plate form, as well as in 304, 304L, 316 and 316L grades.
According to Outokumpu’s Web site, Prodec users are likely to experience better chip breaking, faster machining, decreased risk of notch formation, better dimensional tolerances, enhanced machined-surface quality and more consistent tool performance.
"Prodec 303 is a fully resulfurized, free-machining austenitic stainless steel," said Lou Kern, senior vice president of long products for Outokumpu. "The Prodec name means the steel has been specially melted and treated by Outokumpu proprietary ladle metallurgy techniques.
"When we designed Prodec 303, we wanted a grade that would retain good mechanical properties, like JBA Precision is experiencing," he added. "But we also wanted to be sure the grade would have corrosion-resistance properties, which is critical when the end use is something where aesthetics ‘rule the road,’ such as a motorcycle."
To be sure, a brand like Harley-Davidson doesn’t rule the road without a great attention to detail. With parts fabricators like JBA Precision opting to use enhanced materials like Prodec 303, Harley-Davidson motorcycles and others will undoubtedly keep their long-held reputation for excellence. FFJ
