Series Z1P

Material

Steel - 1018

Part Type

Plate Groove

SGS Product

11/32” Dia, 4 Flute, Square End Mill

Competitor Product

11/32” Dia, 4 Flute, End Mill

Application

Milling: Slotting

SGS Tool Information

0.3438” Cutting Dia
0.8130” Length of Cut
2.5000” Overall Length
TX(Ti-NAMITE-X) Coating

EDP:

36422

Goal

The customer was machining grooves in 1018 steel plate and needed to improve productivity while reducing tool consumption and machining costs.

Strategy

The SGS Application Engineer recommended a Z-Carb-AP end mill and optimized cutting parameters to increase axial depth of cut and maximize material removal rates while maintaining process stability.

Result

The Z-Carb-AP reduced cycle time from 30 minutes to 2 minutes and increased tool life from 5 parts to 75 parts per tool. The customer achieved a 93% reduction in total machining costs and generated annual savings exceeding $124,000.

Total Cost Savings

$124,324

Cycle Time

93%

New Tool Cost

81%

Cost Per Part

90%

Tools	Cutting Dia (DC)	RPM	SFM	IPM	IPR	Radial Depth (AE)	Axial Depth (AP)	Coolant
Z-Carb (4-Flute)	0.3438″	5500	495	64.02	0.0116	0.3438″	0.2000″	Flood
Competitor (4-Flute)	0.3438″	2200	198	14.96	0.0068	0.3438″	0.1000″	Flood

Cycle Time

93%

New Tool Cost

81%

Cost Per Part