Z-Carb-AP

Series ZAP

Material

Titanium Ti-6AI-4V

Part Type

Titanium Shells

SGS Product

1/4” Dia. 4 FLute, Corner Radius End Mill

Competitor Product

0.2500” Dia. 4 Flute Solid End Mill

Application

Milling: Semi-Rough / Profiling

SGS Tool Information

0.2500” Cutting Dia.
0.7500” Length of Cut
2.5000” Overall Length
TX (Ti-NAMITE-X) Coating

EDP:

36601

Goal

The customer aimed to reduce machining cycle time while increasing tool life to boost overall productivity and lower manufacturing costs.

Strategy

Upgraded from general purpose end mills to the Z-Carb AP, featuring variable helix, rake, and flute spacing for higher performance and stability. Although the tool cost was 70% higher, the goal was to offset it through improved efficiency and longevity.

Result

Testing proved highly successful. The Z-Carb AP doubled tool life and delivered a 10-minute cycle time reduction, resulting in 25% faster machining, 8% lower tool cost, and 25% lower cost per part. Overall, the customer achieved $9,233 in total savings, validating the upgrade to a high-performance solution.

Total Cost Savings

$9,233

Cycle Time

25%

New Tool Cost

8%

Cost Per Part

25%

Tools	Cutting Dia (DC)	RPM	SFM	IPM	IPR	Radial Depth (AE)	Axial Depth (AP)	Coolant
Z-Carb-AP (4-Flute)	0.2500″	4584	300	18.34	0.0040	0.2017”	0.0500″	Flood
Competitor (4-Flute)	0.2500″	3820	250	15.28	0.0040	0.2017”	0.0500″	Flood

Cycle Time

25%

New Tool Cost

8%

Cost Per Part