Ball Nose Milling on a Romi – D800 plus. Cycle time down 84%.
A mould customer was machining a Clamp Mold on a Romi – D800 plus. The operation was ball nose milling.
The problem
Reduce operation time and improve finishing. Each part was taking 100 minutes on the machine spindle.
The change
A SPEED Jet/GJet ER32 spindle, to raise rpm and feed. The spindle is driven by the machine’s own high-pressure coolant, so there is no external power supply, no air line and no installation work — it loads and runs like any other tool holder.
The numbers
Same part, same machine, same operation. The only change is the spindle.
| Measure | Machine spindle | SPEED Jet/GJet |
|---|---|---|
| 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 | Average | High |
| Surface Finish | Average | High |
| Metal Removal Rate (cm3/min) | 0.00072 | 0.00372 |
Conditions
- Coolant pressure: 45 bar
- Material and hardness: P20 Steel, 40 HRC
- Cutting tool: ball nose milling cutter
- Tool diameter: 1.5 mm
- Number of teeth: 2
On the machine
The jet spindle runs in the tool holder like any other tool, driven by the coolant the machine already supplies.
What it means
An 84% reduction in cycle time, 84 minutes saved on every part, and $56 a part at a $40/hour machine rate. Tool life moved from average to high, which changes the consumable cost as well as the clock.
The wider point is that the machine spindle was never the limit on this job — the tool was. A small cutter needs surface speed the machine cannot reach, so it gets run slowly and it wears out. A coolant-driven spindle speeder puts the rpm at the tool instead of asking the machine for it.
Read the full case study with every operating parameter or talk to us about your part.
