Overview of Case Studies

Green Jet (GJet) Case Studies

SUCCESS STORY
The customer had excessive wear on the cutters and the finish was not up to EMBRAER standards. Satisfied customer, increased tool life with the Colibri Jet Spindle by 35% and improved engraving finish.

CASE STUDY
Industry	Aerospace Industry
Application	Engraving Finish
Part	Avionics parts
Machine	Mazak Integrex – I-400
Challenge	Drill and Mill in narrow spaces with high quality finish and minimum tool wear.
Solution	The application of GJet/ SPEED Jet reduced time, provided a better finish and increased the life of the cutter.

RESULTS WITH ULTRA Jet/ GJet
Time Savings per part (minutes)	10.73
Cost Savings Per Part ($40/hour)	$7.15

SPEED Jet, GJet

OPERATING DATA	DESCRIPTION OF OPERATION ONE
Test Data	Machine Spindle	Jet Spindle
Spindle Speed (rpm)	11,000	41,000
Cutting Speed (Vc in m/min)	17.00	64.00
Depth of Cut (mm)	0.05
Width of Cut (mm)	0.25
Table Feed (Vf in mm/min)	242	820
Tool life – high, average, low	Average	High
Surface Finish – high, average, low	Low	High
Cycle Time Improvement (in %)	70.5%
Machining Time (min) per part	15.23	4.5

CONDITIONS
Coolant Pressure & Flow rate	20 bar & 10 l/min
Holder Type	ER32
Material & Hardness	15-5PH Stainless Steel (55 HRC)
Cutting Tool	Ball nose end mill (HSB 2005M)
Diameter (mm)	0.5
No. of Teeth	2

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 Milling
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	59,000
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

Additional Information

Video of the Process on Machine

Additional Pictures

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).

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.

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

SUCCESS STORY
The component here in discussion is used in the liquid propellant engines in rockets for launching satellites. Hence the criticality to maintain all the quality parameters was paramount. With huge savings in cycle time, got reduced by 67% compared to previous cycle time. Which gave around 225 hours of machine hour savings with this very premium range of machine.

CASE STUDY
Industry	Aerospace/ Space Industry
Application	Channel milling
Part	Inner Shell – Liquid Fuel Channel
Machine	HMC – DMG
Challenge	Very high cycle time & to maintain the profile of the component.
Solution	Use SpinJet GJET & HPC for high RPM & better run-out.

RESULTS WITH GJet/ SPEED Jet and HPC Jet/ POWER Jet
Time Savings per part (minutes)	13,500 (225h)
Cost Savings Per Part ($40/hour)	$9,000

HPC Jet/ POWER Jet and GJet/ SPEED Jet

OPERATING DATA	DESCRIPTION OF OPERATION ONE		DESCRIPTION OF OPERATION TWO
Test Data	Machine Spindle	HPC Jet Spindle	Machine Spindle	GJet Spindle
Spindle Speed (rpm)	12,000	45,000	12,000	44,500
Cutting Speed (Vc in m/min)	57	212	38	140
Depth of Cut (mm)	0.2		0,15
Total D.O.C. – Hole [mm]	6.0		6.0
Table Feed (Vf in mm/min)	1,200	2,200	800	2,200
Machining Time (min) per part	18,225	6,075	2,025	675
Tool life – high, average, low	Low	High	Low	High
Surface Finish – high, average, low	Same		Same
Cycle Time Improvement (in %)	67%		67%

CONDITIONS
Coolant Pressure & Flow rate	80 bar & 31 l/min
Holder Type	HSK 100
Material & Hardness	Brass & 160HB
Cutting Tool	DHF UNE 150801
Diameter (mm)	1.0 and 1.5
No. of Teeth	2

Additional Pictures

SUCCESS STORY
The goal was producing this bone support plate as fast and efficient as possible.

CASE STUDY
Industry	Medical Industry
Application	Engraving Text on Bone Support Plate
Part	Bone Support Plate
Machine	DMG MORI DMP 70
Challenge	Produce as fast and efficient as possible.
Solution	Use SPEED Jet/ GJet for certain steps.

RESULTS WITH ULTRA Jet/ GJet
Fast and reliable machining with good surface quality.

SPEED Jet, GJet

OPERATING DATA	Part Cutting – Op 6-1	Part Cutting – Op 6-5	Part Cutting – Op 6-6
Test Data	Jet Spindle	Jet Spindle	Jet Spindle
Spindle Speed (rpm)	40,000	40,000	40,000
Cutting Speed (Vc in m/min)	251.00	251.00	251.00
Depth of Cut (mm)	0.07	0.1	0.1
Width of Cut (mm)	2.0	2.0	2.0
fz (mm/t)	0.037	0.037	0.037
Table Feed (Vf in mm/min)	2,960	2,960	2,960

CONDITIONS
Coolant Pressure	40 bar
Holder Type	BT40
Material & Hardness	TiAl6V4
Cutting Tool	EC-A2 020-030
Diameter (mm)	2
No. of Teeth	2

Additional Information

Operations in this Case Study

Orthopedic Bone Support Plate Operations in an Overview

SUCCESS STORY
The goal was producing this bone support plate as fast and efficient as possible.

CASE STUDY
Industry	Medical Industry
Application	Engraving Text on Bone Support Plate
Part	Bone Support Plate
Machine	DMG MORI DMP 70
Challenge	Produce as fast and efficient as possible.
Solution	Use SPEED Jet/ GJet for certain steps.

RESULTS WITH ULTRA Jet/ GJet
Fast and reliable machining with good surface quality.

SPEED Jet, GJet

OPERATING DATA	Text Milling – Op 3-1	Text Milling – Op 3-2
Test Data	Jet Spindle	Jet Spindle
Spindle Speed (rpm)	40,000	40,000
Cutting Speed (Vc in m/min)	38.00	38.00
Depth of Cut (mm)	0.02	0.02
Width of Cut (mm)	0.08	0.08
fz (mm/t)	0.005	0.005
Table Feed (Vf in mm/min)	400	400

CONDITIONS
Coolant Pressure	40 bar
Holder Type	BT40
Material & Hardness	TiAl6V4
Cutting Tool	EC-A2 003-0045/01C4H45
Diameter (mm)	0.3
No. of Teeth	2

Additional Information

Operations in this Case Study

Orthopedic Bone Support Plate Operations in an Overview

SUCCESS STORY
Client with a tool wear problem and excessive machining time. We managed to reduced tool wear, advised the customer to use specific tools for aluminum (he was using them for steel in general), significantly reduced machining time for slotting from 360 minutes to 183 minutes with a much better finish using the GJet Jet Spindle and for finishing from 40 minutes to 30 minutes. GJet was chosen over the HPC due to the limitation on space, otherwise HPC would have been the preferred Jet Spindle for this happy customer.

SUCCESS STORY

Client with a tool wear problem and excessive machining time. We managed to reduced tool wear, advised the customer to use specific tools for aluminum (he was using them for steel in general), significantly reduced machining time for slotting from 360 minutes to 183 minutes with a much better finish using the GJet Jet Spindle and for finishing from 40 minutes to 30 minutes. GJet was chosen over the HPC due to the limitation on space, otherwise HPC would have been the preferred Jet Spindle for this happy customer.

CASE STUDY
Industry	Die & Mold
Application	Profile Milling
Part	Electrode
Machine	HAAS VF4
Challenge	Reduce machining time and achieve an improved finish.
Solution	Applied GJet for its speed, compactibility and accuracy.

RESULTS WITH GJET/ SPEED Jet
Time Savings per part (minutes)	187
Cost Savings Per Part ($40/hour)	$124.67

SPEED Jet, GJet

OPERATING DATA	3D Bottle Finish		3D Slot Finish
Test Data	Machine Spindle	Jet Spindle	Machine Spindle	Jet Spindle
Spindle Speed (rpm)	10,000	24,000	10,000	25,000
Cutting Speed (Vc in m/min)	63	151	157	393
Depth of Cut (mm)	0.3		0.1
Width of Cut (mm)	0.07		0.07
Table Feed (Vf in mm/min)	800	2,000	2,000	5,400
Machining Time (min) per part	40	30	360	183
Tool life – high, average, low	Low	High	Low	High
Surface Finish – high, average, low	Low	High	Low	High
Cycle Time Improvement (%)	25%		49%

CONDITIONS
Coolant Pressure & Flow rate	15 bar at 10 liters per minute
Holder Type	ER32
Material & Hardness	Aluminium 6061
Cutting Tool	Ball nose endmill – 2 teeth
Diameter (mm)	2.0 and 5.0
No. of Teeth	2