From: Grant Preston [mailto:firstname.lastname@example.org]
Sent: Thursday, May 08, 2014 2:40 PM
To: Emil Somekh; Eddie Pevzner
Subject: Amazing iMachining saving!
One of our customers saved AU$3000 on only one of their parts.
They have many similar parts in their product range!
Please see details of case study:
Customer Case Study
Customer: Wallis Drilling (Midvale, WA, Australia)
Focus of Study: Reduce cycle time (main focus on roughing)Case Study
Part: Drill Bit Body
Part Material: K1045 (UTS of 770 applied)
Batch Qty: 90 (usually 50-200 parts)
Original Toolpath Details:
Carbide tipped cutter + 16mm End Mill
Traditional 3D Roughing - maximum depth of cut 3mm
Cycle Time: 100 mins per run of 8 parts (12.5 mins per part)
Consumption of tooling: 9x Carbide Inserts + 16mm End Mill (badly worn)
Cost of tooling: 9x $16 + $92 = $236
Total Machine Time: 18 hours 45 mins
iMachining Toolpath Details:
12mm Carbide End Mill
2D & 3D iMachining Operations - maximum depth of cut 11.3mm
Cycle Time = 30 mins per run of 8 parts (3.7 mins per part)
Consumption of tooling = 12mm End Mill shows signs of wear but will cut more
Cost of tooling: $110 (can still be used)
Total Machine Time: 5 hours 33 mins
Original Toolpath: 12.5 mins per part
iMachining Toolpath: 3.7 mins per part
Cycle Time saving: 8.8 mins per part (a 70% saving)
Total Time saving on batch of 90: 13 hours 12 mins
Total Time saving on batch of 200: 29 hours 20 mins
Example Cost saving (batch of 200): $2933 (based on hourly rate of $100)
Total Saving (including tooling): $3059 (based on hourly rate of $100)
This is only 1 drill bit of many that Wallis produce, so the total savings across their entire product range is incredible!
In applications such as this, return on investment can be achieved in a very short space of time!