“Our fi rst order
was for just six–seven pieces, but we knew it was a job that would be coming back so it was important to get things right the fi rst time,” said Biegel. “We were turning the job on a Mazak Quick Turn 30 and wanted an insert capable of both holding up under the cutting pressures and generat- ing precision results for the entire run. We
Hydraulic piston rods induction-hardened to Rc
50–55
to a case depth of 0.100” (2.5 mm) were threaded using Carmex HBA inserts in lots of 100 with a cycle time of 30 seconds encompassing 16 passes.
thought we would have to go to the expense of CBN until we were contacted by Tim Schubert of Iwen Tool and Supply [Saginaw, MI]. Tim suggested a new prod- uct from Carmex Precision Tools [Richfi eld, WI]—the HBA insert.” “The HBA insert was developed for applications in extremely hard materials. Combining a rugged substrate with nano-coating technology, the HBA delivered superior performance for a number of customers, so I didn’t hesitate to recom- mend it to Paul,” said Schubert. “We were really pleased with the performance, so we decided to try the insert in an even more challenging application. The job involved threading a hydraulic piston rod made from 1045 Thompson shafting induction-hardened to Rc
50–55 to
a case depth of 0.100” [2.5 mm] with a 0.562” [14-mm] diameter. We produce this part in lots of 100 with an annual quantity of about 2000, and we are aiming for a cycle time of 30 seconds encompassing 16 passes,” said Biegel. “We found one other insert that could do the job, but when we applied our price/value analysis, we discovered that it was delivering only 40 parts at a cost per part of $2.98. The HBA insert ran 96 parts per insert at a cost of 21 cents, less than one-tenth of the cost of the other. Computing insert cost and burden rate that amounted to a cost savings of $5533.33,” said Biegel. “New tooling materials such as HBA are really bringing costs down for shops and manufacturers doing hard machining. While CBN is an excellent cutting medium, the need to braze the toolbit to the holder raises the price substantially. We’ve converted over 70 of our customers to HBA and other more economical inserts,” said Schubert.
“It is clear that without establishing a formal review process followed by a
defi ned test protocol, it’s impossible to really understand where your savings and effi ciencies can be found. Just as important, by keeping up with the latest technol- ogy, we can be assured that we’re delivering a better product to our customers. That’s what our Thursday morning meetings are about,” said Alfonso. For more information from Carmex Precision Tools LLC, go to
www.carmexusa. com, or phone 262-628-5030.
February 2015 |
AdvancedManufacturing.org 119
See us at HOUSTEX Booth #514
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