Case Study: H-Carb Series 77 Helps Defense Industry Company Reduce Overall Total Job Cost

Goals

The goal of this opportunity was to reduce overall total job cost by increasing tool life and decreasing cycle time per part.

Strategy

The existing application utilized an indexable shell mill to take a peripheral cut on a 2” thick plate. Subsequently, an end mill was used to clean up the smaller corners and finish the outside. The new strategy utilized a single 7-flute end mill for both operations.

Conclusion & Results

Using the SGS Series 77 end mill, the customer was able to reduce the number of axial passes from 8 to 4 and eliminated the need for an additional tool to peform the clean-up and finishing cuts. Cycle time was decreased from 31 minutes to 9:30 minutes per part, and part count per tool went from 2 to 8. Major improvements were realized in total machining cost, new tool cost, and tool change cost, resulting in annual savings of nearly $89,000.

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