H-Carb

Series 77

Material

Steel - 1018

Part Type

Gear Housing

SGS Product

H-Carb 7-Flute Corner Radius End Mill

Competitor Product

0.500” Dia. 5-Flute Solid End Mill

Application

Milling: Semi-Rough/Profiling

SGS Tool Information

0.500” Cutting Dia.
1.500” Length of Cut
3.500” Overall Length
Chipbreaker
Ti-NAMITE (TM) Coating

EDP:

77191

Goal

Following a change in management, this hardware shop aimed to reduce cycle time and improve tool life using general-purpose end mills. KYOCERA SGS application engineers were tasked with identifying a tool solution that could deliver measurable improvements in efficiency and surface quality through controlled testing and real-world application.

Strategy

The H-Carb Series 77 achieved a tool life of 20 parts prior to observable wear, nearly tripling the performance of the competitor’s tool, which exhibited wear after just 7 parts.

Result

Implementation of the H-Carb end mill led to a 70% reduction in cycle time. Tooling costs decreased by 63%, and cost per part was reduced by 68%. Overall, the customer achieved a 68% total cost reduction, resulting in annual savings exceeding $57,600.

Total Cost Savings

$57,613

Cycle Time

70%

New Tool Cost

63%

Cost Per Part

68%

Tools	Cutting Dia (DC)	RPM	SFM	IPM	IPR	Radial Depth (AE)	Axial Depth (AP)	Coolant
H-Carb (7-Flute)	0.5000”	6601	865	189.45	0.0287	0.0500”	1.3190”	Flood
Competitor (5-Flute)	0.5000”	5158	676	59.32	0.0115	0.0500”	1.3190”	Flood

Cycle Time

70%

New Tool Cost

63%

Cost Per Part