Competitive Analysis
Analysis 1 - Plunger
| Current Tool | |
|---|---|
| Part Name | Plunger |
| Material | P4 Low Alloy General Structural Steel |
| Current Insert | WNMG432-M5 TP3500 |
| Current Tool Life | 70 pcs |
| Current Time in Cut | 51 sec |
| Current Tool Life Time | 59 min 23 sec |
| Current SFM | 721.6 |
| Current Feed | 0.0098 in/rev |
| New Tool - TP3501 | |
| Inserts Description | WNMG432-M5 TP3501 (EDP 49022) |
| Depth of Cut | 0.0787 in |
| # of passes | 1 |
| SFM | 721.6 |
| RPM | 1556 |
| Feed | 0.0138 in/rev |
| Coolant | Yes |
| Tool Life | 90 pcs |
| Time in Cut | 36 sec |
Results showed better application security due to the increased productivity over the existing product. Lowered cost by over 25% due to increased tool life & increased feed capabilities.
Analysis 2 - Shaft
| Current Tool | |
|---|---|
| Part Name | Shaft |
| Material | P5 Structural Steel |
| Current Insert | SNMM646-R4 TP3500 |
| Current Tool Life | 1 pc |
| Current Time in Cut | 2 min 21 sec |
| Current Tool Life Time | 2 min 21 sec |
| Current SFM | 721.6 |
| Current Feed | 0.0098 in/rev |
| New Tool - TP3501 | |
| Inserts Description | SNMM646-R57 TP3501 (EDP 61361) |
| Depth of Cut | 0.1969 in |
| # of passes | 1 |
| SFM | 360.8 |
| RPM | 117 |
| Feed | 0.0315 in/rev |
| Coolant | Yes |
| Tool Life | 11 pcs |
| Time in Cut | 2 min. 21 sec |
| Tool Life Time | 25 min. 51 sec |
Results showed better application security due to the increased wear resistance over the existing product. Lowered cost by over 40% due to increased tool life.
Analysis 3 - Differential Carrier
| Current Tool | |
|---|---|
| Part Name | Diff Carrier |
| Material | Nodular Iron |
| Current Tool Life | 150pcs |
| Time in Cut | 28 sec |
| Coolant | Yes, 6% flood and thru tool 500 PSI |
| New Tool - R220.8 | |
| Tool Description | R220.88-02.50-12-07A |
| Inserts Description | SNMU120410TN-MD13, MK1500 |
| Depth of Cut | 3mm - (varies due to casting) |
| Width of Cut | 22mm |
| # of passes | 1 |
| SFM | 654.5 |
| RPM | 1,000 |
| Feed per tooth | 0.011" |
| Feed | 78.74 in/min |
Results showed better application security due to the higher depth of cut capability over the existing product. Lowered cost by 25% due to increased number of edges.