Combining Machining Operations into a Single Tool Cuts Machining Costs and Improves Process Control

Making the change to multi-function cutting tools has benefits far beyond the savings generated through reduced manufacturing time. Here are some benefits and how they add to making your machining operations faster and more efficient.

Hole making tools: multi-function tools come in a countless number of shapes and sizes. For hole making traditional step twist drills, straight flute G-drills, and helical flute subland drills offer advantages to reduce machining time. Porting tools, having been around for a long time, offer this same advantage.

Tru-Edge “Dreamer” tools eliminate reaming and secondary honing operations, providing fine surface finishes. Designed to solve production time issues, these tools combine G-Drill concepts with multi-burnishing lands for round, straight holes, and superior surface finishes. For deep hole chip evacuation (greater than 5X diameter drilling depth), coolant- fed tools are essential for flushing chips and providing lubrication for burnishing, especially in vertical and horizontal machining applications. “Dreamer” tools feature unique geometries based on the material and can be resharpened and recoated. They also reduce overall part processing costs by eliminating secondary operations and producing tight tolerance holes and fine surface finishes, potentially eliminating post-process honing.

Form Tools: special side milling form tools decrease cycle times and offer the same advantage of increasing machine up time. Multi-function rotating tools like dovetail cutters, fir-tree mills, spline form cutters, and special T-slot/keyseat cutting tools are effectively reducing machining cycle times.

With the onset of 5-Axis machining, the machine tool builders have opened the door for innovative cutting tool engineering teams to design special form tools that produce part features in one set-up. Elements of rotating, multi-function circular form tools are endless due to the ever-increasing complexity of CNC cutter grinders. Tru-Edge incorporates innovative CAD/CAM software in the tool design phase to match forms to part print specifications then applies its knowledge of cutting tool geometries to match the material being machined.

An application example of Tru-Edge expertise to design + grind rotating tools was producing a spline form on a rotating tool applied to a machining center process. The form, flute style, tool geometry and clearance angles along with proper application of the carbide substrate and PVD coating – all handled in-house – made this project an overwhelming success.

Considerations for Chip Making: Benefits of reduced manufacturing cycle time is straight forward and easily figured out using a burden rate x machining time calculation. However, there are additional savings that go well beyond cycle time reduction.

• Hole making often requires a SPOT DRILL, a DRILL, a CHAMFER TOOL, and maybe a COUNTERBORE tool. Using special designed tools can reduce 4 operations to ONE.
• 4 operations + 4 distinct tools ≠ 4 set-up costs
  
  • Each cutting tool must be ordered, received, stocked, and accounted for in the tool crib.
  • Each tool must be programmed by CNC programming.
  • Each tool requires its own set-up and preset requirements.
  • Each tool requires a tool-holder, a stud bolt, a collet if using collet holders, maybe a Weldon-type holder, and at times high value high-cost precision holders like hydraulic chucks or ultra-precision holding units.
  • Each tool takes up a pod in the machine carousel and in the case of four tools versus ONE tool we can rationalize that four tool changes versus ONE tool change = increased machining time and less spindle up time.
  • Four tools open the door to four tool failures while ONE tool oftentimes provides a higher level of process control.
  • Four tools open the door for four offset errors while ONE tool oftentimes requires no tool offsetting.

BOTTOM LINE: One appropriately designed special cutting tool reduces the hidden costs by a factor of 5X or more ... when taking into consideration the total costs that include procurement + receiving + stocking + inventory. Add to that the cost for tool holder assemblies + preset time. Add to that the engineering time to program the tools. And maybe as important as anything the advantage of process control of one tool versus multiple tools.

Every tool used in the chip making process has all these cost elements. Partnering with Tru-Edge where we Simplify Tooling™ to provide competitive advantage through exceptional design + build of special cutting tools will minimize your cost and drive profit to the bottom line.

At Tru-edge Simplify Tooling™ is what we do every day!

If you want to learn more on how you can improve the life of your cutting tools when machining iron-based materials give us a call at 419-678-4991 or visit our website at www.tru-edge.com. We’ll get our TE Tech Team involved and simplify your iron-based machining processes!