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Case Study

Clamp Mold - Finishing

SUCCESS STORY
The test passed with flying colors, with a three-fold increase in rpm compared to the original, and a five-fold increase in feed. Much better surface finish. An 84% reduction in the operating cycle. A very satisfied customer.
CASE STUDY
Industry Mold Industry
Application Ball Nose
Part Clamp Mold
Machine Romi – D800 plus
Challenge Reduce operation time and improve finishing
Solution SPEED Jet/GJet ER32 spindle application – Increase rpm and feed
RESULTS WITH ULTRA Jet, GJet
Time Savings per part (minutes) 84
Cost Savings Per Part ($40/hour) $56
SPEED Jet, GJet
OPERATING DATA Face Ball-nose Milling
Test Data Machine Spindle Jet Spindle
Spindle Speed (rpm) 15,000 49,000
Cutting Speed (Vc in m/min) 71 231
Depth of Cut (mm) 0.03 0.03
Width of Cut (mm) 0.04 0.04
Table Feed (Vf in mm/min) 600 3,100
Machining Time (min) per part 100 16
Tool life – high, average, low Average High
Surface Finish – high, average, low Average High
Metal Removal Rate (cm3/min) 0.00072 0.00372
Cycle Time Improvement (in %) 84%
 CONDITIONS
Coolant Pressure 45 bar
Holder Type Ball Nose Milling Cutter
Material & Hardness P20 Steel, 40 HRC
Cutting Tool Ball Nose Milling Cutter
Diameter (mm) 1.5
No. of Teeth 2
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