You need better tools to run faster and smarter. Optimizing the cutting tool for the machine tool to run at the fastest possible speeds is an important factor where CNC has an advantage over a manual ground tool.

• Better tools last longer

• Tool life becomes more predictable since the tools are more consistent. You can schedule your tool changes to get the full life of the tool but NOT to suffer any interruptions. And your tool changes will be LESS frequent than with manually ground tools. You will also know how many tools you need based on your production schedule and the turn-around time in getting tools serviced.

• Plus you’ll be able to shrink your tool inventory.

• Better cuts.  Less heat.  Cuts the way you expect from the start.  You’ll get better parts with less scrap

• Cuts with less vibration, less heat, so machine tool doesn’t wear as much.  Therefore you have lower maintenance on the machine tool.

Why faster feeds are so important. Sandvik Coromant surveyed manufacturers and concluded that tool price and tool life don’t matter much in potential savings.  They published their finding in just about every major metalworking magazine, but let’s review them together.

Here they presented a typical example totaling all the production costs that go into a part: Cutting tools and the workpiece material, which are the only really variable costs on an individual job, plus the fixed costs for the machinery, labor, building and overhead. The total cost per part works out to $10.

Using this example, Sandvik asked what would happen if you got a 30% discount on the cost of the cutting tools?  And on the next slide we see that…

Why faster feeds are so important. By giving a 30% discount on the cost of the cutting tool we don’t really get any advantage.  You save only 1% on the final production cost.

So then they asked, “What would happen if the tools lasted 50% longer?”  And the next slide shows.....

Why faster feeds are so important. A 50% longer tool life actually has the same effect:  Just a 1% savings on the cost of the part.

Now, what if the cutting tools gave you only a 20% improvement in cutting speed?

Why faster feeds are so important. Notice that even with a 50% increase in the cost of the tool, the 20% productivity increase amounts to a 15% cost savings (assuming the machinery and labor can be put to other jobs).  And I assure you that the difference between CNC and manually ground tools can EASILY be a 20% increase in cutting speeds.

This same idea would apply to other time saving ideas, like the Automated Toolroom concept I’ll touch on later.