Energy & Gas Case Studies

SUCCESS STORY
Client with a tool wear problem and excessive machining time. We managed to reduced tool wear, significantly reduced machining time from 30 minutes to 2 minutes with a much excellent surface finish using the HPC/POWER Jet Spindle. The customer could improve the parts per cutting edge by 25 and had productivity savings of 85%.
CASE STUDY
Industry Energy – Gas and Oil
Application Face Ball-nose Milling
Part Gas Turbine housing
Machine INTEGREX e-1060V/8 II
Challenge Long Cycle Time
Solution Use of the HPC/POWER Jet Spindle
RESULTS WITH POWER/HPC Jet
Time Savings per part (minutes) 28
Cost Savings Per Part ($40/hour) $18.67
POWER Jet, HPC Jet
OPERATING DATA Face Ball-nose Milling
Test Data Machine Spindle Jet Spindle
Spindle Speed (rpm) 3,000 22,000
Cutting Speed (Vc in m/min) 9.18 88.00
Depth of Cut (mm) 0.18 0.36
Width of Cut (mm) 0.975 1.281
Table Feed (Vf in mm/min) 1,013 7,665
Machining Time (min) per part 30 2
Tool life – high, average, low Low – 1 part per tool High – 25 parts per tool
Surface Finish – high, average, low Average High
Metal Removal Rate (cm3/min) 0.2753 4.154
Cycle Time Improvement (in %) 93.4%
 CONDITIONS
Coolant Pressure 20 bar
Holder Type ER11
Material & Hardness A36, INO 316, 4140
Cutting Tool EB-A2 015-012/06C4H45 702
Diameter (mm) 1.5
No. of Teeth 2

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