OSG Phoenix PFB high precision indexable ball end mill boosts performance in metal mold application with faster cycle, longer tool life and much improved surface quality
Located in Löchgau, Germany, Stickel GmbH is a manufacturer of sophisticated sheet metal parts and assemblies made of steel, aluminum and stainless steel for prototypes, test construction and serial production. Employing nearly 100 staff, Stickel is equipped with some of the latest machines and facilities servicing major international automotive manufacturers in Europe. Stickel’s core competence is the production of small and medium-sized structural components up to 1,200 mm in length in areas such as the body, engine, chassis, no longer available spare parts for expired series, and assemblies.
Stickel’s core competence is the production of small and medium-sized structural components up to 1,200 mm in length in areas such as the body, engine, chassis, no longer available spare parts for expired series, and assemblies. Images courtesy of Stickel.
Stickel manufactures sheet metal forming parts in small quantity. The company also produces the molds for these workpieces. Due to the small lot size, the molds do not have to be hardened and can be made from cast iron or low carbon steel materials such as ST52. Although ST52 is easy to machine, the tolerance of ingredients is very large. Due to this nature, the work material can vary greatly lot by lot, making it a major challenge for Stickel to reach good surface quality at high feed rates. The sheet metal parts are up to 1,200 mm in length. The molds are measured at similar sizes and are made of steel and cast iron.
Stickel is an existing OSG tool user. During a recent visit to the company’s manufacturing facility, OSG GmbH Technical Sales Representative Sven Clement wanted to help Stickel tackle the challenge of processing improvement. Upon a detail evaluation of the application, Clement recommended the dia. 16 mm PFB indexable ball end mill from the OSG Phoenix indexable series.
From left to right, Stickel Production Manager Thomas Birkenmaier, OSGGmbH Technical Sales Representative Sven Clement and Stickel Owner Matthias Stickel pose for a photograph at Stickel’s manufacturing facility in Löchgau, Germany.
The OSG Phoenix PFB is a high precision indexable ball end mill engineered for superior surface finish and tool life. Its spiral cutting edge enables excellent cutting edge strength and sharpness. The PFB’s steel and carbide tool shanks help reduce chattering and provide favorable milling surface when machining at short or long overhangs. This indexable ball end mill series is most ideal for 3-D finishing operations where precision and surface finish are critical. The PFB offers an array of inserts suitable for steel, stainless steel, cast iron, high hardened steel and non-ferrous metal applications.
The OSG Phoenix PFB is a high precision indexable ball end mill engineered for superior surface finish and tool life. This indexable ball end mill series is most ideal for 3-D finishing operations where precision and surface finish are critical. The PFB offers an array of inserts suitable for steel, stainless steel, cast iron, high hardened steel and non-ferrous metal applications.
Stickel’s molds are processed using a Hermle machining center. The tolerance requirement for accuracy is approximately 0.02 mm. The previous cutting tool was used at a maximum feed rate of 1,500 mm/min. The PFB, on the other hand, is capable of running at a maximum feed rate up to 4,000 mm/min. By switching to the PFB indexable ball end mill, Stickel is able to nearly triple cycle time. Moreover, the durability of the PFB almost doubled that of the competitor tool. Last but not least, the surface quality has significantly improved to the point that some polishing processes can be eliminated, enabling Stickel to reach greater efficiency in their manufacturing process.
The OSG Phoenix PFB indexable ball end mill nearly tripled cycle time and doubled tool life while significantly improved surface quality in Stickel’s metal mold application.
For more information on the OSG Phoenix PFB finishing ball end mill and Stickel GmbH
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