H-Carb

Series 77C

Material

Steel - 4140

Part Type

Weight Distributing Hitch

SGS Product

5/8” Dia, 1-9/16” LOC, 5/8” Shank Dia Corner Radius End Mill

Competitor Product

0.6250” Dia. 7 Flute End Mill

Application

Milling: Semi-Rough / Profiling

SGS Tool Information

0.6250” Cutting Dia.
1.5625” Length of Cut
3.7500” Flute Length
TM (Ti-NAMITE-M) Coating

EDP:

77215

Goal

An automotive parts manufacturer approached a KYOCERA SGS Application Engineer at a trade show seeking to improve tool life with a solution designed for high-efficiency milling in 4140 steel.

Strategy

The part, used in a weight-distributing hitch, was machined on twin Muratec MT200 machines using two 5/8” end mills to pinch mill a 1-3/8” solid round bar with bar feeders and a robotic unloader. Due to limited spindle power and part geometry, climb milling at 7% radial engagement and 406 SFM was required to maintain stability. Under these parameters, the SGS 77215 doubled tool life, achieving 130 total parts or 65 per tool, compared to the competitor’s 32.5 parts per tool.

Result

Implementation of the H-Carb led to a 50% reduction in the number of tools required. Total change costs decreased by 50%, and cost per part was reduced by 47%. Overall, the customer achieved a 47% total cost reduction, resulting in annual savings exceeding $201,000.

Total Cost Savings

$201,744

Tools Required

50%

Tool Change Cost

50%

Cost Per Part

47%

Tools	Cutting Dia (DC)	RPM	SFM	IPM	IPR	Radial Depth (AE)	Axial Depth (AP)	Coolant
H-Carb (7-Flute)	0.6250″	2480	406	109.89	0.0443	0.0420″	1.3750″	Flood
Competitor (7-Flute)	0.6250″	2480	406	109.89	0.0443	0.0420″	1.3750″	Flood

Tools Required

50%

Tool Change Cost

50%

Cost Per Part