Case Studies
We not only believe our product is one of the best on the market. . . so do many of our customers and other professionals. Please read the testimonials, success stories, and/or articles below. Please contact us to share your own success stories!
Manufacturing Engineering Magazine - January 2002 issue
"Old Tool Design Takes Off" - Author Jim Destefani - Senior Editor
"Milling and boring tools with inserts that rotate during cutting promise significant productivity improvements in machining of tough material"
Metal Master HP Cutter Improves Productivity
One of Rotary's customers had a difficult time machining 1074 hot rolled alloy steel. The part was a blade used for cutting strips of sod from the ground. The workpieces ranged from 12" to 24" in length, 1/4" to 2" in width and had to be machined at a 12 degree angle to achieve the desired cutting edge of the blade which produced a variable depth of cut from .250" to 0. The cutter that was being used was a 5" diameter with 12 inserts. Due to the difficult cutting conditions the machine was set at 680 rpm and a feed rate of 19 ipm. This job was time consuming and the finish that was produced was 125 rms.
After observing this machining process a solution was suggested. The customer was offered Rotary Technologies 6" HP style cutter. The HP609 proved to be a winner! Tests showed that the spindle speed could be increased by 60% and the feed rate was nearly tripled to 54 ipm. In addition to the increased productivity, the finish was improved to 30 rms and the insert life was doubled.
Metal Master MFS203 Flycutter Comes to the Rescue
A tool and die shop located in Indiana manufactures plastic injection molds. The molds are made of D2 die steel and are approximately 6" square. The workpieces are machined on a 3HP Supermax which was set to run at 1000 rpm, 4"-6" ipm and has a depth of cut of .100". The heavy cuts taken by a conventional 2" flycutter with carbide inserts resulted in extreme wear.
The customer needed to improve his productivity. The solution was the Metal Master MFS203 2" flycutter. The machine spindle speed was increased to 1500 rpm and the feed rate was virtually doubled to 10 ipm. Due to the unique shape of the Frustum insert only a small turn is required to expose a new cutting edge. The Frustum insert can be indexed up to 24 times depending on the depth of cut. Needless to say tool life was greatly increased! The customer not only increased his through put but reduced his cost per piece.
MM300 Improves Productivity While Maintaining Critical Flatness
Customer was faced with face milling small blocks of 2024 aluminum. The cut face is approximately 4" square and the drawing specified a surface finish of 125RMS. The most important criteria was maintaining flatness. The surface flatness had to be held within .001". The customer was using a 3" diameter traditional cutter with (3) triangular inserts. The machining parameters were 5000 rpm, 30" per minute (3500 sfm, .002 ipt)and a depth of cut from .005" to .010". To prove out the Metal Master MM300 the customer substituted his current cutter. They increased the speed to 7000 rpm (40% faster) and increased the feed rate to 50" per minute. In spite of the faster feeds and speeds the surface flatness was held to +/- .0005". Due to the shallow depth of cut the customer was able to index the unique Frustum style insert 30 times!!!. Indexing was reduced to every other week and annual insert costs were reduced by 45%.
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