MANUFACTURED BY MITGI: Reducing cycle times

We work with customers who serve a wide range of industries – medical device, aerospace, automotive, defense, firearms, rapid prototyping, mold making, and more. Although specific needs vary by industry, a common goal is to reduce cycle times. Whether part of a cost reduction initiative or as a way to increase output, reducing cycle times through tool design can be achieved in many different ways.

With so many tool options to consider, how does a person decide where to start? For most of our customers, we begin with an email or a short phone call to better understand the application and determine what is important to achieve. With or without tool prints, our technical team can suggest tool options that may help to reduce cycle times and accomplish key initiatives.

How does this play out?

EXAMPLE 1


Application: COMPANY A wants to achieve shorter cycle times by increasing material removal rates
Material: Ti-6Al-4V
Tool type: 6-Flute High Performance End Mill
Coating: AlTiN
MITGI mix:

  • Tapered core for increased rigidity
  • Variable helix geometry dampens vibration and improves part finish
  • Geometry optimized for full axial depth of cut in dynamic or trochoidal milling strategies
  • Radial relief provides a stronger edge that can better withstand high feed rates

Add-on Request: COMPANY A would like to increase tool life thereby reducing overall project costs
MITGI recommendation: Upgrade to NACO coating. This coating will provide added heat resistance and more lubricity. This low-cost upgrade will deliver longer tool life

EXAMPLE 2

Application: COMPANY B has a turning application and wants to create a grooved feature and establish feature height in a single plunge
Material: Inconel
Tool type: 2-Flute Coolant Thru Trepan Tool
Coating: AlTiN
MITGI mix: 
  • Two holes deliver coolant to the cutting edge, thereby reducing heat and removing chips
  • Custom coolant thru design increases tool life while cutting inside of a bore where coolant wouldn’t normally reach
  • Custom design ensures consistent results and form accuracy
Add-on request: COMPANY B wants to reduce chances of chipping
MITGI recommendation: Add edge break by introducing a small radius, therefore reducing the chance of premature chipping

MANUFACTURED BY MITGI: Chip control

Every machinist knows the importance of chip control and just how easy it is to take for granted when it’s working well. When it isn’t, it can be a real headache until a solution is found. Luckily, there are many options to consider that could help alleviate chip-related issues: helix modifications, chip breakers, using coolant to remove chips, optimizing the geometry for chip load, and many more. Working with a cutting tool manufacturer allows customers to choose the option that works best for the job and materials at hand.

How does this play out?

EXAMPLE 1

Application: COMPANY A is a firearms manufacturer and needs a tool to create a thin-walled slot
Material: Steel
Tool type: Custom form keyseat cutter

Coating: None
MITGI mix:

  • Forms on alternating teeth designed to optimize chip load and increase tool life
  • Staggered geometry helps to reduce vibration, improve finish, and minimize production inconsistencies
  • Dished on both sides to produce clearance and alleviate rubbing or binding

Add-on Request: COMPANY A would like to increase tool life thereby reducing overall project costs

MITGI recommendation: Add more teeth to the form. With more teeth to engage, the tool life will increase resulting in reduced tool quantities over the life of the job.

EXAMPLE 2

Application: COMPANY B specializes in hydraulic components; facing tight time constraints, COMPANY B is creating a tapered form and places high priority on part finish
Material: Aluminum
Tool type: Custom tapered reamer
Coating: None
MITGI mix: 
  • Ample core to optimize tool strength and rigidity
  • Spiral flute with material specific helix to provide efficient chip removal
  • Flute geometry and strong cutting edges designed to reduce chatter and improve finish
  • Custom rake applied to help avoid the tool grabbing the part
  • Geometry designed to alleviate tool pullout from holder

 

Want to schedule a time to meet with our team? We’re adept at working remotely to handle questions, troubleshoot technical issues, and discuss new ideas. We’re available by phone, email, ZOOM, Skype, and Microsoft Teams. Contact us today or book an appointment for you and your team.