H-Carb

Series 77MS

Material

Cast Iron - Ductile

Part Type

Planet Carrier

SGS Product

10.00mm Dia, 7 Flute, Square End Mill

Competitor Product

0.3937” Dia. 1 Flute End Mill

Application

Milling: Finishing

SGS Tool Information

0.3937” Cutting Dia.
1.1811” Length of Cut
3.1496” Overall Length
TM (Ti-NAMITE-M) Coating

EDP:

74409

Goal

The customer wanted to decrease tool cost, improve part quality and surface finish, and increase tool life by moving away from a competitor’s custom tool and into a standard tooling solution.

Strategy

The existing process used a custom indexable cutter that expanded inside the bore to finish multiple surfaces, requiring spindle stops to retract the insert. SGS recommended switching to an H-Carb end mill and using a radial finish-milling approach.

Result

The new approach improved surface finish and extended tool life while significantly reducing tooling cost and lead time by replacing a special with a standard tool. Machining cycle time was reduced by 14%, machining cost decreased by 14%, and cost per part was reduced by 31%, resulting in total cost savings of $348,448.

Total Cost Savings

$348,448

Machining Cycle Time

14%

Machining Cost

14%

Cost Per Part

31%

Tools	Cutting Dia (DC)	RPM	SFM	IPM	IPR	Radial Depth (AE)	Axial Depth (AP)	Coolant
SGS H-Carb (7-Flute)	0.3937″	3500	361	19.60	0.0056	0.1000″	1.0000″	Flood
Competitor (1-Flute)	0.3937″	3000	309	3.00	0.0010	0.1000″	0.0100″	Flood

Machining Cycle Time

14%

Machining Cost

14%

Cost Per Part