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Special Solution - Face Mills

Success Cutting Some Nasty Zirconium!

Ingersoll applies our Series 9DKG Combination cutter in Zirconium, and shows the customer how to realize almost $23,000 in increased profitability while machining a single part!

A large, Tier-1 manufacturer had been roughing and finishing 320 BHN zirconium blocks using a competitor's 10.00” face mill.

Customer: Medical

Application: Pre-Machining Zirconium Blocks

Material: 320 BHN Forgings

Solution: Ingersoll 9DKG Power-Max Combination Face Mill

Improvement: Nearly $48,000 in increased profitability on just two parts!

We replaced the competitor's cutter with a 12.00" diameter Ingersoll 9DKG series combination face mill, including a YCE434 wiper in the face-mounted pillow-block. He increased their feedrate from .0022 IPT to .011 IPT, and the end result was an increase in MRR to 39.9 from the previous 0.74! In addition, machinists were able to machine 22% more parts before indexing inserts, and got a 13-15 RMS finish to boot!

Ingersoll clearly showed this customer that the least expensive cutter/insert combination rarely returns the lowest total manufacturing cost. With further attention, we believe that we can show this customer over $50,000 in cycle-time reductions using Ingersoll Cutting Tool products.
[Postscript: In another test on the same machine, on another Zirconium forging, we showed the customer how to increase profits by another $25,000 over what the competitor's cutter had been giving them!]

Our new customer is now a true-believer in the value of Ingersoll Cutting Tool products and our tooling professionals in the field.

Clearly a win-win situation for the customer...and Ingersoll!

-John Larsen, Ingersoll Cutting Tools

 
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