END USER: Kustom Machining LLC, (715) 258-2908, www.kustommachiningllc.com.
CHALLENGE: Improve productivity for a repeat job.
SOLUTION: A multifunctional, 90° indexable-insert shoulder cutter.
SOLUTION PROVIDER: OSG USA Inc., (800) 837-2223, www.osgtool.com.

When it comes to machining precision metal parts, a manufacturer's competitive advantages in quality, performance and cost-efficiency play critical roles. Successful companies constantly look for ways to reduce costs while improving process efficiencies.

Kustom Machining LLC, Waupaca, Wis., wanted to achieve that for a repeat job that involved machining an idler bracket board feeder for the paper industry on a 25-hp Milltronics VMD 30/100 vertical milling machine. Founded 4 years ago by machining and fabrication veteran Kelly Much, the machine shop also produces parts for the agriculture, defense, aerospace, health care and aquatic industries.

The job requires removing 0.600 " (15.24mm) of material from a 1020 steel workpiece to create the 7 "-long × 3 "-wide (177.8mm × 76.2mm) part. Much was applying a shoulder mill 1 " (25.4mm) in diameter tooled with three inserts at a spindle speed of 2,500 rpm and a feed rate of 20 ipm (508 mm/min.), or 0.0027 ipt (0.0686 mm/tooth).

Kustom Machining produces 36 idler bracket board feeders for the paper industry each month. Image courtesy Kustom Machining.

"We were doing these parts over and over, and the cycle time seemed long," Much said, adding that there had to be something that would speed up production.

He noted 1020 is a type of hot-rolled steel that is slightly gummy, so chip control can be an issue. In addition, Kustom was consuming six inserts to complete the job, which consists of 36 parts and repeats monthly.

Much consulted with Dustin Loschiavo, district manager for Glendale Heights, Ill.-based toolmaker OSG USA Inc. Loschiavo recommended the company's Phoenix PSE 90°, 1 "-dia. shoulder cutter tooled with three inserts.

Much tested that cutting tool along with three other brands. According to Much, the other brands performed either a little better or a little worse than the original tool, but not the one from OSG. "The OSG tool worked way better," he said.

OSG's Phoenix PSE 90° shoulder cutter is suitable for roughing and finishing, including facemilling, side milling, slotting, ramping and helical milling. Image courtesy OSG USA.

The Phoenix PSE tool cut the 1020 part at a spindle speed of 3,200 rpm, a cutting speed of 800 sfm (243.84 m/min.) and a feed rate of 50 ipm (1,270mm), or 0.0039 ipt (0.0991 mm/tooth). Running at those parameters allows the shop to reduce the cycle time by 5 minutes per part, saving 3 hours of time per job.

After switching to the OSG tool, the workpiece material's gumminess is no longer an issue. "OSG must have the right geometry on the insert," Much said. "The chips are flying off as sixes and nines just like they're supposed to."

With the new tool, the shop only consumes four inserts to complete the entire part run, saving the expense of two inserts. And that savings comes without paying a premium for the tools. "The inserts are the same price as what we were using," Much said.

In addition to the 1020 job, Much applies the Phoenix PSE shoulder cutter to machine stainless steel and other steel products. "They save a lot of time on the other parts that we do," he said.

That helps maximize the efficiency of his lighter-duty machine tools, some with only 15 hp, Much said. "They're great on my little machines. They can take bigger cuts without stalling the machines."

Much is glad his milling tool tests resulted in a productivity improvement. "I'm always willing to try what's out there," Much said. "We welcome reps like Dustin who dedicate their time and energy to finding better cutting tool solutions."