Helix application review increases tool life by 60% and saves £8,400 a year
Inconsistent tool life was driving up costs and interrupting production for a manufacturer machining stainless steel. A Helix Tools application review found the cause and delivered a 60% improvement.
The challenge
The customer was machining a range of stainless steel components on a vertical machining centre with a standard carbide milling cutter. The parts were acceptable, but tool life was unpredictable and cutters were typically being replaced after around 18 components. Each change added cost and interrupted production.
The customer asked Helix Tools to find out why tool life was so inconsistent, and whether it could be improved without compromising quality or output.
How Helix solved it
Helix’s applications engineer carried out a full review of the application on site, looking at the material, component geometry, existing tooling and cutting conditions. The review identified the root cause. The general-purpose cutter and carbide grade weren’t suited to stainless steel, which work-hardens and generates high heat at the cutting edge, so wear was rapid and erratic.
Helix specified an alternative milling cutter and carbide grade matched to the material and set revised cutting conditions so the new tool would perform at its best. Helix then ran a production trial, monitoring tool wear, component quality and consistency, and fine-tuned the process before recommending wider roll-out.
The result
Average tool life rose from 18 to 29 components, an increase of more than 60%. Helix’s analysis of the customer’s annual volumes showed this reduces carbide consumption and saves an estimated £8,400 a year in tooling costs.
Tool performance is now predictable, so there are fewer unplanned stoppages and the customer has greater confidence in the process.
