Boosting tool life by more than 2,000%

A defense systems manufacturer based in the Midwest known for their precision work and commitment to quality faced a critical challenge in producing parts using forgings. Initially, they invested in a 30-taper CNC machine, which proved inadequate for the job. The lack of rigidity and spindle resonance negatively impacted tool life, preventing the manufacturer from achieving the desired results.

Determined to find a solution, they initially turned to well-known brands, purchasing end mills costing more than $250 each. Despite the high price tag, the tool life was disappointing, averaging only 55 parts per end mill at a feed rate of 60 inches per minute (ipm).

Everything changed when they discovered GWS Tool Group’s Alumigator end mills and broaching tools from their armory line of products.

By switching to GWS Alumigator tools – including 3/8" and 1/4" end mills, as well as 1/2" ball nose end mills, the manufacturer saw tool life skyrocket to 1,500 parts per end mill, a remarkable improvement.

“I’ve replaced pretty much everything with Alumigators for high-volume work,” the customer said. “These tools just excel, and I’ve never had one fail.”

The enhancements didn’t stop at tool longevity. The customer also experienced significant efficiency gains, with machine feed rates increasing from 60ipm to 130ipm at 16,000rpm. In terms of cycle time, they reported a reduction of approximately 20%. The broaching tool was also a game-changer, delivering flawless performance from the start.

GWS Tool Group
https://www.gwstoolgroup.com