All Case Studies

Case Study

Gear milling - Pocket milling

SUCCESS STORY
We applied the GJet ER32 Spindle – we increased the rpm and Vf., we did the roughing with direct finishing in one step (the original was done in two steps – roughing and finishing).

CASE STUDY
Industry Automotive
Application Pocket milling
Part Gear with undercut
Machine HAAS VF4 Vertical Machining
Challenge Reduce operation time – Improve surface finish – Avoid tool breakage.
Solution We applied the GJet ER32 Spindle – we increased the rpm and Vf., we did the roughing with direct finishing in one step (the original was done in two steps – roughing and finishing).
 
RESULTS WITH GJet/ SPEED Jet
Time Savings per part 2.5 min/ 70%
Cost Savings Per Part ($40/hour) 1.68$
GJet/ SPEED Jet
OPERATING DATA DESCRIPTION OF OPERATION
Test Data Machine Spindle Jet Spindle
Spindle Speed (rpm) 10,000 31,000
Cutting Speed (Vc in m/min) 47 146
Depth of Cut (mm) 0.5 0.23
Width of Cut (mm) 0.3 0.2
Table Feed (Vf in mm/min) 200 1,199.7
Machining Time (min) per part 3.6 1.1
Tool life – high, average, low high high
Surface Finish – high, average, low average high
Cycle Time Improvement (in %) 70
Total Machining Time (min) per part 1.1
 CONDITIONS
Coolant Pressure & Flow rate 20 bar
Holder Type ER32
Material & Hardness 4140 Steel
Cutting Tool ISCAR End Mill. Toroidal
Diameter (mm) 1.5
No. of Teeth 2
CONTACT US

Accessibility Toolbar