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Automotive Case Studies

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

Additional Information

Video of the Process on Machine

SUCCESS STORY
Customer used 3 stages of slot milling before getting to the result. We increased the RPM from 8,000 to 30,000 – We reduced two semi-finishing stages (1.5 and 0.8 mm cutters) to one finishing stage with a 1.0 mm cutter. The customer achieved 65% reduction in operating time. Customer was very satisfied with the result.
CASE STUDY
Industry Automotive and Die & Mold Industry
Application Slot Milling
Part Headlight Lens Mold
Machine Haas UMC 1000
Challenge Increase machine speed to reduce machining time – Eliminate semi-finishing step (1.5 and 0.8 cutters) – Improve finishing aspect.
Solution We applied a SPEED Jet/ GJet Er32 Spindle with a 1.0 mm ball nose cutter straight to the finish – we increased the speed and feed rate.
RESULTS WITH ULTRA Jet/ GJet
Reduction from 3 Cutting stages to only 1.
65% reduction in operating time on machine.
Jet Spindle GJET V4
SPEED Jet, GJet
OPERATING DATA Slot Milling
Test Data Machine Spindle Jet Spindle
Spindle Speed (rpm) 8,000 30,000
Cutting Speed (Vc in m/min) 25.1 94.2
Depth of Cut (mm) 0.05 0.03
Width of Cut (mm) 1.00
Table Feed (Vf in mm/min) 1,500 3,000
Tool life – high, average, low Low High
Surface Finish – high, average, low Low High
Cycle Time Improvement (in %) 65%
 CONDITIONS
Coolant Pressure & Flow rate 20 bar & 10 l/min
Holder Type ER32
Material & Hardness P20 steel (32 HRC)
Cutting Tool Ball Nose
Diameter (mm) 1.0
No. of Teeth 2
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