Z-Carb HPR

Series Z5C

Material

Cast Iron - Ductile Cast Iron

Part Type

Actuator

SGS Product

3/4” Dia, 5 Flute, Corner Radius End Mill

Competitor Product

0.7500” Dia. 2 Flute End Mill

Application

Milling: Slotting

SGS Tool Information

0.7500” Cutting Dia.
0.8750” Length of Cut
4.0000” Overall Length
TM (Ti-NAMITE-M) Coating

EDP:

37096

Goal

This manufacturer was interested in improving part quality and finish.

Strategy

The customer was originally running a two-flute indexable end mill with four inserts, achieving about 60 parts per insert but frequently destroying an average of three tool bodies per month, an added cost factored into the evaluation. After testing the Z-Carb HPR, we were able to run more aggressively while significantly increasing tool life. The improved performance and reduced tooling costs led to a highly satisfied customer and a clear win for the HPR solution.

Result

The implementation of the Z-Carb HPR resulted in a 70% reduction in the number of tools required. Cycle time reduced by 18%, and total machining costs were reduced by 18%. Overall, the customer achieved a total cost reduction of 34%, generating annual savings of more than $17,000.

Total Cost Savings

$17,355

Tools Required

70%

Machining Cycle Time

18%

Total Machining Cost

18%

Tools	Cutting Dia (DC)	RPM	SFM	IPM	IPR	Radial Depth (AE)	Axial Depth (AP)	Coolant
SGS Z-Carb-HPR (5-Flute)	0.7500″	2000	393	50.00	0.0250	0.7500″	0.4320″	Flood
Competitor (2-Flute)	0.7500″	1000	197	15.00	0.0150	0.7500″	0.4320″	Flood

Tools Required

70%

Machining Cycle Time

18%

Total Machining Cost