A customer is producing job shop blue print work for the automotive, agriculture, and plastic industries. They are manufacturing end caps from structural steel using a Mazak AJV 6080 VMC running with water soluble coolant The end cap requires 4 tapped holes per part.
The pipe tap was being torn by the thread, which resulted in the poor tool life. Unsatisfied with their current process, the customer needed to reduce the cost of production and increase tool life.
The AccuThread 856 blew the customer away by the increase in productivity.
| Product: |
AccuThread 856 Solid Carbide |
| Objectives: |
(1) Increase tool life
(2) Decrease costs |
| Industry: |
General machining |
| Part: |
End Cap |
| Material: |
Structural Steel |
| Hole Ø: |
1.20" (30.48mm) |
| Hole Depth: |
0.7515" (19.088mm) |
The AccuThread 856 thread mill
- Solid carbide thread mill: TMNK1000-NPT
| Measure |
Competitor |
AccuThread 856 |
| RPM |
10 |
2156 |
| Speed |
0 SFM (0 M/min) |
350 SFM (106.68 M/min) |
| Feed Rate |
0.010 IPR (0.254 mm/rev) |
0.002 IPR (0.0508 mm/rev) |
| Penetration Rate |
0.10 IPM (2.54 mm/min) |
2.17 IPM (55.118 mm/min) |
| Cycle Time |
39 min 15 sec |
3 min 36 sec |
| Tool Life |
1 hole |
192 holes |
| AccuThread 856 offered 96% cost per hole savings over the competitor tooling. |
The AccuThread 856 thread mill provided:
- 96% cost per hole decrease
- Increased tool life
- Decreased cycle time