Z-Carb-HPR

Series Z5C

Material

Inconel 718 (AM)

Part Type

Hot Gas Manifold

SGS Product

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

Competitor Product

0.7500” Dia. 6 Flute Solid End Mill

Application

Milling: Semi-Rough / Profiling

SGS Tool Information

0.7500” Cutting Dia.
1.5000” Length of Cut
4.0000” Overall Length
AlTiN (Ti-NAMITE-A) Coating

EDP:

38642

Goal

A customer requested a test of the Z-Carb HPR to reduce cycle time during part production.

Strategy

SGS application engineers replaced the competitor’s tool with a 3/4” Z-Carb HPR end mill and increased the radial stepover from 10% to 12%. As a result of this adjustment, cycle time was reduced, and it’s believed that further improvements in tool life or cutting parameters are possible with a change in the current toolholder.

Result

Implementation of the Z-Carb HPR led to a 11% reduction in cycle time. New tool costs decreased by 12%, and cost per part was reduced by 11%. Overall, the customer achieved a 12% total cost reduction, resulting in annual savings exceeding $12,000.

Total Cost Savings

$12,131

Cycle Time

11%

New Tool Cost

12%

Cost Per Part

11%

Tools	Cutting Dia (DC)	RPM	SFM	IPM	IPR	Radial Depth (AE)	Axial Depth (AP)	Coolant
Z-Carb-HPR (5-Flute)	0.7500″	404	79	6.06	0.0150	0.0900″	0.2250″	Coolant Through
Competitor (6-Flute)	0.7500″	458	90	9.34	0.0204	0.0750″	0.2250″	Coolant Through

Cycle Time

11%

New Tool Cost

12%

Cost Per Part