HPC cutting tool improves manufacturing capacity

volume part that was proving difficult to machine and as a result was subcontracted by IMS.

When the volumes were increased, the subcontractor demanded an increase per part.

The result was that it was brought back in house, the tooling technology was revisited and by working with WNT (UK) the cycle time on these parts was reduced by 66 per cent.

This one-time problem component is now a profitable part for the business.

Smith said: 'Not only is the performance of the HPC cutter exceptional but the fact that it is available with such a wide range of corner radii is resulting in major savings.

'Corner radii are very specific in the aerospace sector as they are fracture points.

'This meant we were spending a large amount on having cutters ground with specific corner radii.

'Now, with HPC we can get standard cutters that match our requirements, with the added advantage of being able to achieve tolerance and surface finish with a single pass, which has reduced tooling costs as only one cutter is required.

'This is on top of the cycle time savings that range from 33 to 50 per cent.'
Another typical application is an aviation-grade steel component that has an observation window machined into it.

Due to the interrupted cut, IMS used to require a total of two tools and five passes to machine this feature.

Now, by using an HPC cutter with the correct corner radius, this operation is achieved in a single pass at higher feed rates, resulting in a cycle time reduction from five minutes down to 42 seconds.

Along with the increased productivity also came increased tool life, with the HPC cutter machining more than 250 parts before it required changing compared with only 40 parts from the previous tools.

This equates to a saving in tooling costs of around GBP900 over 250 parts.

To keep this cutting-tool technology under control, IMS has taken the next step and installed a WNT Toolomat tool-vending system.

Previously the company had operated a conventional consignment stock system but this was not monitored or controlled very well.

Smith said: 'Switching to the Toolomat system we are now fully in control of tool usage.

'The system is secure, and we always have the right tools in stock but we are only invoiced on what is dispensed.'
Of particular value to IMS is the regular reporting that is provided by the system, which allows close monitoring of tool usage.

When workloads change it enables WNT (UK) to react and adjust stock levels as and when required.

The system can also be tailored to suit an individual company's requirements as far as dispensing tools and reporting are concerned.

Individual machines, operators or components can be tracked to highlight any patterns of usage that may emerge.

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