The customer manufactures automotive spot welding electrodes made from copper. They use a Daewoo Puma MS running with a ChipBlaster coolant pump to produce their products.
Looking for improvements, the customer needed to reduce cycle time, increase tool life, and lower the cost of production.
The EcoCut tooling reduced cycle time and increased tool life for the customer.
| Product: |
EcoCut |
| Objective: |
Decrease cycle time |
| Industry: |
Automotive |
| Part: |
Spot welding electrodes |
| Material: |
Copper |
| Hole Ø: |
0.025" (0.635 mm) |
| Hole Depth: |
0.625" (15.875 mm) |
EcoCut multifunction tooling
- EC 08R-2.25D 04-E
- XCET 040102FR-27P H216T
| Measure |
Previous Tooling |
EcoCut |
| |
Solid carbide drill
- Hole Ø: 0.3750” (9.525 mm)
- Depth: 0.710” (18.034 mm)
- Cycle time: 3 sec
- Tool life: 7500 parts
Carbide bar
- Hole Ø: 0.4375” (11.113 mm)
- Depth: 0.710” (18.034 mm)
- Cycle time: 19 sec
- Tool life: 9500 parts
Turning/facing tool
- First Pass
- Hole Ø: 1.50” (38.100 mm)
- Depth: 0.650” (16.510 mm)
- Second pass
- Hole Ø: 0.625” (15.875 mm)
- Depth: 0.025” (0.635 mm)
- Cycle time: 1.2 sec
- Tool life: 11,500 parts
|
First pass
- Hole Ø: 0.3150” (8.001 mm)
- Depth: 0.710” (18.034 mm)
- Cycle time: 4.5 sec
Boring pass
- Hole Ø: 0.4375” (11.113 mm)
- Depth: 0.710” (18.034 mm)
- Cycle time: 6 sec
Turning operation
- Hole Ø: 1.50” (38.100 mm)
- Depth: 0.650” (16.510 mm)
- Cycle time: 7.8 sec
Final pass
- Hole Ø: 0.625” (15.875 mm)
- Depth: 0.025” (0.635 mm)
- Cycle time: 0.2 sec
|
| Tool Life |
11,500 parts |
50,000 parts |
| Cycle time |
47.2 sec |
18.5 sec |