SHOP SOLUTIONS
When suddenly faced with a rush order for a family of sixteen big injection mold blocks, retooling the cavity hogging operation shaved a week off the delivery schedule and about $10,000 in machining costs on that job alone for Shaw In- dustries. And now they’re applying the same practices plant- wide for an expected annual saving of more than $100,000. “And it is just a drop-in retooling,” said Shaw foreman Steve Knight.
The new tool, a Gold Quad F face mill from Ingersoll
Cutting Tools (Rockford, IL), seemed an unlikely choice for the Shaw applications. Introduced about two years ago, it is nominally a high-feed tool tailored for fast, shallow passes. Yet at Shaw Industries it is excelling at depths of cut ap- proaching 0.100" (2.54 mm). Other mold shops using the same tool are running this high-feed face mill as deep as 0.075" (1.9 mm).
Running 22/5, Franklin’s 37-man mold and welding shop is accustomed to big work, including structural fabrications weighing up to 15 tons (13.6 t).
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Left to right: Shaw’s Steve Knight, Ingersoll’s Dennis Hawke, and Allegheny Tool’s Josh Jolley collaborated on one challenging rough milling job, leading to an enterprise-wide projected savings of $100,000 a year.
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AdvancedManufacturing.org | January 2016
He tried out one new cutter. It improved the removal rate slightly but the inserts wore out too soon and cost a lot more. So he asked Josh Jolley of Allegheny Tool and Supply (Franklin, PA) for a better solution. Jolley brought in Dennis Hawke of Ingersoll to demo the Gold Quad F. Based on experience, Hawke was confi dent that it could increase throughput at least 25% and be just a drop-in replacement. “Though primarily a high-feed tool, it has proven out in scores of deeper-cut applications, so we were confi dent it would work,” said Hawke.
“We were moderately satisfi ed with our rough milling
processes on hardened mold blocks,” said Shaw foreman Steve Knight, “but we always felt there was a better way.” Their standard parameters with a 3" (76-mm) face mill were 485 rpm, 650 sfm (198 m/min) 0.040" (1-mm) depth of cut and 100 ipm (2540 mm/min). Whenever they pushed further, the inserts would shatter, often triggering a cycle of reworking the part and repairing the cutter or fi xturing. It was the big mold order, with its tight schedule, that gave Knight the impetus to look for a better way. Each of the sixteen blocks measured 24 x 36 x 8" (610 x 914 x 203 mm), weighed about a ton and required hogging out 600 lb (272 kg) of hardened P20 material to create the mold cavities. “Five tons of stock to remove in all, with not much time to do it,” Knight added.
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