Case Study 16 of Industrial Engineering ONLINE Course
2017
The story of toolholder change at Wescast Industries Inc., the world’s largest manufacturer of cast exhaust manifolds and turbocharger housings for passenger cars and light trucks.
The annual cost-savings for change of toolholder, from the additional tool life on Wescast’s 16 CNC machine line, factoring direct and indirect labor costs as well as tool change savings, was $78,269.
The new toolholder was Haimer's shrink fit toolholder. The regional manager for HAIMER USA, presented Wescast with a proposal that would guarantee both increased productivity and tool life versus their current collet chuck holders. He promised reducing cycle time by 5% for all round tools with the guarantee that Wescast would net a minimum increase in tool life of 25% for all tools using shrink chucks.
The Test
To test the proposal, one machining cell (8 machines) and five cutting tools was used to conduct a study. The part was cast iron exhaust manifolds. In four machines, the existing collet chuck holders were left to run as usual, without changing cutting parameters. In the other four machines, HAIMER shrink fit chucks replaced the pre-existing collet chucks with adjustments to feeds and speeds to generate the 5% improvement for each tool. During the following three months, data was carefully gathered as all machines continued operating across three shifts, six to seven days per week. Data including cycle times, tool life and tool change times were recorded.
Results – Tool Life
After three months, the data was examined. The improvements in tool life from the tools in shrink fit chucks were profound, achieving an average life increase of 60% across all five tools. Tool life, which was measured by the number of manifold pairs the tools could produce, increased anywhere from 25% to 100% depending on the tool. The annual cost-savings from the additional tool life on Wescast’s 16 CNC machine line, factoring direct and indirect labor costs as well as tool change savings, was $78,269.
HAIMER claims the significant increase in life is a bi-product of their systems runout accuracy, balance integrity, taper accuracy and inherent ability to maintain the aforementioned properties from one tool change to the next.
https://www.haimer-usa.com/news/blog/blog-articles-pages/2017/71917-shrinking-costs.html
Top 10 reasons to use HAIMER shrink fit technology
The story of toolholder change at Wescast Industries Inc., the world’s largest manufacturer of cast exhaust manifolds and turbocharger housings for passenger cars and light trucks.
The annual cost-savings for change of toolholder, from the additional tool life on Wescast’s 16 CNC machine line, factoring direct and indirect labor costs as well as tool change savings, was $78,269.
The new toolholder was Haimer's shrink fit toolholder. The regional manager for HAIMER USA, presented Wescast with a proposal that would guarantee both increased productivity and tool life versus their current collet chuck holders. He promised reducing cycle time by 5% for all round tools with the guarantee that Wescast would net a minimum increase in tool life of 25% for all tools using shrink chucks.
The Test
To test the proposal, one machining cell (8 machines) and five cutting tools was used to conduct a study. The part was cast iron exhaust manifolds. In four machines, the existing collet chuck holders were left to run as usual, without changing cutting parameters. In the other four machines, HAIMER shrink fit chucks replaced the pre-existing collet chucks with adjustments to feeds and speeds to generate the 5% improvement for each tool. During the following three months, data was carefully gathered as all machines continued operating across three shifts, six to seven days per week. Data including cycle times, tool life and tool change times were recorded.
Results – Tool Life
After three months, the data was examined. The improvements in tool life from the tools in shrink fit chucks were profound, achieving an average life increase of 60% across all five tools. Tool life, which was measured by the number of manifold pairs the tools could produce, increased anywhere from 25% to 100% depending on the tool. The annual cost-savings from the additional tool life on Wescast’s 16 CNC machine line, factoring direct and indirect labor costs as well as tool change savings, was $78,269.
HAIMER claims the significant increase in life is a bi-product of their systems runout accuracy, balance integrity, taper accuracy and inherent ability to maintain the aforementioned properties from one tool change to the next.
https://www.haimer-usa.com/news/blog/blog-articles-pages/2017/71917-shrinking-costs.html
Top 10 reasons to use HAIMER shrink fit technology
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