OSG Phoenix PSF 4-corner shoulder milling cutter improves cost per unit in automotive component production
Hao Tian | OSG Shanghai
With the advancement of the automotive industry, the utilization of stainless steel materials in automobile components is becoming increasingly common, such as 201, 304 and 316 grade stainless steels. 201 and 304 grade stainless steels are relatively easy to process. 316 stainless steel, however, presents greater difficulty in terms of machinability due the larger amount of impurities it contains, which gives the material property a higher hardness. As a result, the machining of 316 stainless steel requires a higher cutting force and the tool cutter edges are exposed to a high level of heat, notch wear and built-up edge. In order to machine 316 stainless steel effectively, the use of high quality professional cutting tools is essential.
A manufacturer of automotive parts located in eastern China, whose name cannot be disclosed due to confidentiality reasons, wanted to improve productivity on their fuel injection nozzle component production made of 316L stainless steel. Established in 2006, this manufacturer has over 1,000 employees and has been producing this part for more than five years. The estimate annual output of the component is more than 1.5 million pieces, with each batch averaging 50,000 pieces. The company had previously tested cutting tools from several providers, but none could achieve satisfactory results. Recently, the project leaders contacted OSG through a distributor to seek assistance, hoping to find a balance between tool life and processing efficiency.
The machining plane of a fuel injection nozzle component made of 316L stainless steel. Due to the presence of a gap in the blank, inaccurate cutting depth is pronged to occur during machining.
OSG Shanghai’s engineers were dispatched to investigate the application at the manufacturing site. The field equipment used is a FANUC ROBODRILL machining center (BT30) equipped with a side lock holder. For roughing, the cutting speed is set at 250 m/min (rotational speed 3,200 min-1), a feed rate per flute of 0.13 mm/t (feed rate 1,248 mm/min), and a depth of cut of 1 mm. For finishing, the cutting speed is set at 400 m/min (rotational speed 5,000 min-1) and a feed rate per flute of 0.1 mm/t (feed rate 1,500 mm/min).
The estimate annual output of the fuel injection nozzle component is more than 1.5 million pieces, with each batch averaging 50,000 pieces.
For mass production in small machining centers, OSG’s technical team recommended the straight shank type OSG Phoenix PSF 4-corner shoulder milling cutter. The OSG Phoenix PSF is a series of 90-degree indexable shoulder end mills and facemills. The OSG Phoenix PSF is designed to achieve optimal performance in compact machining centers with long tool life and high efficiency for short cutting depth applications under 3 mm. Its sharp 3-dimensional chip breaker can effectively reduce spindle load to enable high-speed machining. Utilizing a 4-cornered square insert, highly economical milling is made possible with long insert life and low cost per edge. The compact insert size allows for lighter depth of cut.
OSG Phoenix PSF 4-corner shoulder milling cutter straight shank type. The OSG Phoenix PSF is designed to achieve optimal performance in compact machining centers with long tool life and high efficiency for short cutting depth applications under 3 mm.
OSG Phoenix PSF 4-corner shoulder milling cutter bore type.
Four types of inserts are available to accommodate a wide variety of applications and materials. For this particular application, OSG recommended the GL insert, which is optimal for low-resistance processing and materials such as heat-resistant alloys as well as other difficult-to-machine materials. For convenience and to secure the tool, the customer cut a flat notch in the arbor of the PSF 4-corner shoulder milling cutter by wire cutting.
The GL insert is optimal for low-resistance processing and materials such as heat-resistant alloys as well as other difficult-to-machine materials.
During the cutting trial, the PSF is able to reduce machining vibration to a minimal and achieve a lower spindle load versus the previous tooling choice. Under identical cutting condition, the PSF is able increase tool life by 50 percent while meeting the manufacturer’s cutting speed requirement and ensuring a superior surface finish. The client could not be more satisfied with the improved result.
Manufacturers today are confronted with evolving requirements such as processing stability, quality, tool life and overall cost efficiency. OSG will continue to innovate and provide new solutions to meet the standard of tomorrow.